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mark.capp
L Plate Warrior



Joined: 26 Mar 2020
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PostPosted: 21:36 - 26 Mar 2020    Post subject: Suzuki AY50 Reply with quote
Hi, the forks on my ay50 2004 need replacing.

Has anyone replaced them ? does another brand fit ? e.g. yahama ?
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Nobby the Bastard
Harley Gaydar



Joined: 16 Aug 2013
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PostPosted: 22:06 - 26 Mar 2020    Post subject: Re: Suzuki AY50 Reply with quote
mark.capp wrote:
Hi, the forks on my ay50 2004 need replacing.

Has anyone replaced them ? does another brand fit ? e.g. yahama ?


Are they bent? Is the chrome knackered?. Do the seals need replacing?
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Riejufixing
World Chat Champion



Joined: 24 Jun 2018
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PostPosted: 22:08 - 26 Mar 2020    Post subject: Re: Suzuki AY50 Reply with quote
mark.capp wrote:
Hi, the forks on my ay50 2004 need replacing.

Why?
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mark.capp
L Plate Warrior



Joined: 26 Mar 2020
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PostPosted: 07:49 - 27 Mar 2020    Post subject: Re: Suzuki AY50 Reply with quote
Riejufixing wrote:
mark.capp wrote:
Hi, the forks on my ay50 2004 need replacing.

Why?


The dampening is no longer there and they are greased forks no oil
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mark.capp
L Plate Warrior



Joined: 26 Mar 2020
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PostPosted: 07:51 - 27 Mar 2020    Post subject: Re: Suzuki AY50 Reply with quote
Nobby the Bastard wrote:
mark.capp wrote:
Hi, the forks on my ay50 2004 need replacing.

Has anyone replaced them ? does another brand fit ? e.g. yahama ?


Are they bent? Is the chrome knackered?. Do the seals need replacing?


The dampening is no longer there and they are greased forks no oil

A replacement set is about £80 but they maybe the same state that I’m in. How long they will last I don’t know ?
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Riejufixing
World Chat Champion



Joined: 24 Jun 2018
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PostPosted: 11:17 - 27 Mar 2020    Post subject: Re: Suzuki AY50 Reply with quote
mark.capp wrote:
The dampening is no longer there and they are greased forks no oil

I was interested by that, so looked at the manual. It looks as though they are ffairly simple to take apart:

Fork assy/disassy: https://www.manualslib.com/manual/1082902/Suzuki-Ay50.html?page=106#manual

Parts: https://www.cmsnl.com/suzuki-ay50-1999-x_model13123/partslist/FIG39.html

Component 11 ("damper"(?)) is €1.50. Any use?
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pepperami
Super Spammer



Joined: 17 Jan 2010
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PostPosted: 17:12 - 27 Mar 2020    Post subject: Re: Suzuki AY50 Reply with quote
Riejufixing wrote:
mark.capp wrote:
The dampening is no longer there and they are greased forks no oil

I was interested by that, so looked at the manual. It looks as though they are ffairly simple to take apart:

Fork assy/disassy: https://www.manualslib.com/manual/1082902/Suzuki-Ay50.html?page=106#manual

Parts: https://www.cmsnl.com/suzuki-ay50-1999-x_model13123/partslist/FIG39.html

Component 11 ("damper"(?)) is €1.50. Any use?


I was impressed how quickly you found the relevant information about a bike you’ve not come across before, and what websites to look at Thumbs Up
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Riejufixing
World Chat Champion



Joined: 24 Jun 2018
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PostPosted: 18:12 - 27 Mar 2020    Post subject: Re: Suzuki AY50 Reply with quote
pepperami wrote:
I was impressed how quickly you found the relevant information about a bike you’ve not come across before, and what websites to look at Thumbs Up

Thank you! As I said, I was interested in how it works. I assume the "damping" is done by that double-ended rubber thing (!) rubbing against the spring, lubricated by oil from the grease. I wonder whether the suspension performs reasonably. Sounds to me as though when it's worn it must be like having the front wheel bolted onto a couple of pogo sticks!
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2wheelLover51
Two Stroke Sniffer



Joined: 17 Oct 2019
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PostPosted: 20:40 - 27 Mar 2020    Post subject: Forks Reply with quote
Are you sure the rubber does the damping? it looks to me like the damping happens further down the fork tube with that (Teflon?) bushing. The rubber thing looks like a bump-stop rubber to prevent bottoming out over bad bumps/potholes etc. I would try adding oil and see if the damping improves Very Happy
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Riejufixing
World Chat Champion



Joined: 24 Jun 2018
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PostPosted: 20:49 - 27 Mar 2020    Post subject: Re: Forks Reply with quote
2wheelLover51 wrote:
Are you sure the rubber does the damping? it looks to me like the damping happens further down the fork tube with that (Teflon?) bushing. The rubber thing looks like a bump-stop rubber to prevent bottoming out over bad bumps/potholes etc. I would try adding oil and see if the damping improves Very Happy

Sure? No, not at all! Cmsnl calls that rubber thing a "RUBBER,STOPPER" so it could be a just a bump stop. It could have two purposes, no idea. The damping fluid could be air, but I doubt it, and it wouldn't run out! It might be damped by grease being squeezed about. The idea of Teflon, though, is to reduce friction and slide easily. It's all very fascinating. I wonder if the OP (or anyone else!) knows.
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Nobby the Bastard
Harley Gaydar



Joined: 16 Aug 2013
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PostPosted: 21:24 - 27 Mar 2020    Post subject: Reply with quote
No. 1 is the damper. As it's near the top one assumes some sort of oil is involved.

One wonders why it has oil seals if it doesnt have fork oil in it.
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trevor saxe-coburg-gotha:"Remember this simple rule - scooters are for men who like to feel the breeze on their huge, flapping cunt lips."
Sprint ST 1050
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Riejufixing
World Chat Champion



Joined: 24 Jun 2018
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PostPosted: 21:40 - 27 Mar 2020    Post subject: Reply with quote
There's a service manual here:

https://www.motorscooterguide.net/Manuals/Suzuki_AY50_Service_Manual.pdf

On p. 108 it says:

"Apply grease (15g) to the damper and springs" 99000-25010 SUZUKI SUPER GREASE "A"

When installing the upper spring 1 and damper 2 face the smaller diameter end of the upper spring and the hollow end of the damper towards the wheel."

So that rubber thing is the damper. Extraordinary.

Last edited by Riejufixing on 21:44 - 27 Mar 2020; edited 1 time in total
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Riejufixing
World Chat Champion



Joined: 24 Jun 2018
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PostPosted: 21:43 - 27 Mar 2020    Post subject: Reply with quote
Nobby the Bastard wrote:
No. 1 is the damper. As it's near the top one assumes some sort of oil is involved.

One wonders why it has oil seals if it doesnt have fork oil in it.

It used to have grease in it.....
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Nobby the Bastard
Harley Gaydar



Joined: 16 Aug 2013
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PostPosted: 21:54 - 27 Mar 2020    Post subject: Reply with quote
I suspect the damper is rubber or similar and just uses friction against the fork stantion to damp it.

Just replace that and regrease.


(No oil eeals, the use of an oil seal tool is recommended. )
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trevor saxe-coburg-gotha:"Remember this simple rule - scooters are for men who like to feel the breeze on their huge, flapping cunt lips."
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Riejufixing
World Chat Champion



Joined: 24 Jun 2018
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PostPosted: 22:32 - 27 Mar 2020    Post subject: Reply with quote
Perhaps the OP will tell us what he's done. I think the book says the circlips must be replaced after stripping the forks, but it's still a cheap fix.
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Old Thread Alert!

The last post was made 4 years, 28 days ago. Instead of replying here, would creating a new thread be more useful?
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