Question:
How do i remove the damper bolt out of the forks of a Suzuki GS500E?
VTrider
2009-06-14 20:28:16 UTC
I'm rebuilding the forks on my wife's "98 Suzuki GS500E and I can't get the damper bold out at all. I have the service manual for the bike and I don't see any part of the instructions that I'm missing. I'm an experienced mechanic but this one is stumping me for some reason. What am I missing?
Four answers:
anonymous
2009-06-14 21:19:24 UTC
Oh those things can be a nuisance.



I assume the damper Bolt just spins?

If thats the prob,,

I further assume you have the Fork Springs removed?



I cheat---I use an air wrench,,,the sudden torque and sheer speed never fails.



At home without air tools,,,it helps to leave the springs in the fork ,,with fork caps on.



The Damper Rod is "the lower spring seat" inside the fork leg,,,

so the spring load helps hold the damper rod from turning while You're trying to Undo the bolt that holds the fork together.



Another "cheat" if you already have the springs out,,,is to stick a mop handle down the fork,,,and PUSH HARD.

That will put enough friction on the damper rod to hold it from turning while removing bolt.

Most of the time,anyway.



Best way Really is to have the spring installed.



Don't worry about the fork hand-grenading when you remove the bolt "while under Spring Pressure".



It's NOT under spring pressure,,ever.



The Damper Rod bottoms out in the fork leg in fully extended position.

When you Compress the Fork,,,the Damper Rod goes Up Into the Fork Leg.

Then when it rebounds//Fork Exntends//...Dampre Rod comes back OUT of the Fork,,but only so far.



The OUTER fork tube is bolted to end of Damper,,,all it does is ride along with the damper.



The Spring is trapped inside the Inner Fork Leg,,between Cap & Damper.



Nothing comes flying apart when ya remove Damper Bolt,,except Fork Outer Tubes "fallin off" by gravity

Actually,,they are stopped from separating by Seals/Upper Bushing.



Try re-installing the springs,,,then try the bolt again



When ya go to Reassemble,,guess what?



Same Deal in reverse.

Ya Gotta Hold the Damper Rod from turn while installing & tightening bolt.

Air Wrench works like Magic,,,,otherwise The Springs being installed put enough bind on Damper Rod tp prevent / minimize turning while Ya get Bolt tightened.



Hope that makes sense

That bolt is a silly-simple thing,,,which only makes it Double Annoying when it wont cooperate



Good Luck
ferino
2016-10-31 13:47:38 UTC
Damper Rod
guardrailjim
2009-06-15 08:33:31 UTC
Like TXm42 said, remove the bolt with the spring installed and the fork cap on, to hold the spring in.



Use a socket driver - not an allen wrench

A socket driver is an allen bit on a 3/8 drive socket.

http://buy1.snapon.com/catalog/item.asp?P65=&tool=all&item_ID=1261&group_ID=274&store=snapon-store&dir=catalog



Insert the allen socket into the bolt and SLAM it a few times with a metal hammer - it will help to shock the bolt lose.



Then remove the bolt with a hand held impact driver. http://www.sears.com/shc/s/p_10153_12605_00947641000P?keyword=impact+drivera



OR air impact wrench.
john h
2013-11-22 03:23:56 UTC
When undoing the lower bolt, it is necessary to drop the head of a long long bolt down into the tube,

so to engage a matching HEX SHAPE in the bottom. once in place then run out the lower bolt ensure not to lose the small copper washer. refer to pic.


This content was originally posted on Y! Answers, a Q&A website that shut down in 2021.
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