Let me show you how to replace the fork seals on the Suzuki DR650
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- เผยแพร่เมื่อ 15 ก.ค. 2024
- Dino’s Tinker Shed, S2-Ep34 How to replace the fork seals on the Suzuki DR650
Fork seal replacement can be an intimidating project for many home mechanics, myself included, but it does not have to be. With a bit of planning, research, and a few specialized tools you too can accomplish this project with little to no drama.
This is a long video for sure, but I wanted you to see all the steps and what to expect if you choose to tackle this project. As I say in the video you will require a few specialized tools whether you buy them or make them yourself, but the investment will be less than if you have a shop do the work and guess what? You have the tools forever and knowing that seals wear out you can use them again on your bike or a friend’s if needed.
As always and because this video is so long, I have included time code chapters for you to skip around if needed.
Hope you enjoy it, Dino
Time code chapters:
00:00- Cold opening
00:52- Introduction
01:11- Overview of the project
04:29- Pre work cleaning
06:39- Importance of a manual
07:44- How to remove the front wheel
11:40- Removing the fork tubes from the bike
14:56- Disassembly of the fork tubes
20:56- Specialized tools
28:03- Inspection of old seals
28:52- removing old seals and bushings
30:59- DR650’s lower fork option
33:31- Fork oil selection
35:21- Fork reassembly
39:20- New seal installation
43:12-Filling with oil
46:52- Installing forks back in the bike
47:30- Installing front wheel
49:56- Summary
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Another great video on the DR - thank you Dino I'll need to do this service at some point. One thing I wanted to point out is when you tightened the front axle holder you said to tighten in a criss cross pattern however the manual I have (I think it's the factory Suzuki manual but not positive) says to tighten the two upper nuts first. It even has a photo indicating there should be clearance on the bottom of the axle holder but none on top. Seems counter-intuitive to me, but that's what I've been doing for years.
Lol , I need to follow my own advice and read the manual, I missed that! I'll pin this so others can benefit from it. Thank you so much for the catch.
Dino
Great video Dino. Agree with your philosophy regarding tools vs paying a shop to do something you can do yourself. That fork oil was the dirtiest i have ever seen!
It was nasty oil for sure, I should have changed it when I got the bike.
Thank you for the comment.
Dino
I own a different bike but your video should be a good reference for most fork seal replacements. Good job.
Thank you for the comment glad you enjoyed it
Dino
You are a wonderful teacher.... Always a pleasure to join you in your "Shed". Greetings from France. I just bought a DR650RSES of 1995 (with only 6200km on it), looking forward to riding it.
Thank you for the kind words, I am glad you enjoy the content. Have fun with your new ride.
Dino
Ready for replacing the seals, after giving a look to your video a couple of times, now I feel confidence to do so. Nice you even share torque specifications for each screw.
Your videos are like going to school for the hobby we like. Thank You so much, keep the good work.
Cheers from Monterrey, Mex.
Thank you for the kind words, I try to get as much information in the video as I can, but as an amateur, I do miss things at times. It is always good to review DIY videos from multiple sources before you tackle a new project to see it from different perspectives, other you tubers such as @MOTODANS , @BikerBytes , @BikerBits and @FULLPELTAdventures just to name a few, have great content that I use often to produce my videos, especially when I have not done something before. I am confident that you will be successful in the seals, just take you time and you will do fine.
Thank you again for the comment.
Dino
Really appreciate your videos! They all come in very handy when I need to service my first bike, a very well-used, mighty DR650
Glad you like them!
Dino
Well, after watching the video where you stripped out your oil pan drain bolt, you have now redeemed yourself!
Beautiful clear concise instructions and good video work.
It was so difficult to watch you stripping out the drain plug but I do appreciate you showing screw-ups as we all do them. Excellent video thank you for the good work.
Ya the footage from the drain bolt was quite old and not the best quality. Glad you enjoyed this one.
Dino
@@DinosTinkerShed hey dino, the video quality of the striped oil drain bolt was not the problem.
Watching you continually turn the bolt clockwise the wrong way was really hard! :-)
but that's why I said it was good of you to post it.
I used to teach new technologists in the field that I used to work in and I would always point out my past failures that I had.
It's a good humbling technique because not enough of us are humble! :-)
I am planning to purchase a DR650 next year. Your videos are detailed, entraining and very informative.
Thank you for the feedback, I'm glad you find them useful and good luck on the DR purchase 👍
Dino
Great video! I did the seals on my FZ6 a few months ago for the first time. 53k miles on them. It was intimidating at first, but it was easier then I expected. I just bought a DR650 a month ago to replace the FZ6 as my daily.
I've watch many of your videos and enjoy them all. Kind of has the same feel as the TV show Home Improvement. Excellent information.
It couldn't hurt to add something like Patreon.
Thank you for the comment and I'm glad you enjoy the content. Thank you also for the feedback on Patreon.
Dino
Great video as usual Dino, I love your in depth DIY vids, as I use them to do my DIY on my DR, Thank you!
Your Wellcome glad you enjoy the content.
Dino
I love how step by step and simple your videos are made. I make installing the axle easier by lowering the jack so the wheel and the suspension holes are level, making sliding the axle through simple and smooth. Also, waiting to tighten the axle 4 screws until after compressing the shocks to find the center alignment is important then tighten the axle side 4 screws, this way the shock arms are allowed to balance side to side.
Great tips, thank you for sharing
Dino
Hey Dino, I'm a fellow Ontarian up in Etobicoke. Found your channel a few days ago. You're a gem. I also own a brand new 2022 DR650, first bike ever. Did 5K on it already in the last 90 days.
However I'm having a problem. Everything is stock, except for my Yoshimura RS-2 slip on. I was told that rejetting and changing things isn't really needed, but it will be if I do anything else and want to eliminate popping/backfiring. My issue is that about a month ago, after extended rides on the highway (especially), my bike begins to die. Suddenly the throttle while in 5th becomes less responsive, jerky, and I need to keep giving it throttle for the bike to stay alive, but if I let go of the throttle too long and coast, or downshift into 4th, the bike dies.
Once the bike dies, it's almost impossible to get the bike started again, with or without choke. Sometimes I'm able to by giving it throttle while hitting the ignition, and then there is a TON of white smoke I need to BLOW past and rev for a while. This issue repeats itself, even when I've switched back to the stock exhaust.
In your expertise, what do you think this is? Is it the bike running too lean? If so, why would it create so much white smoke and have so much trouble starting up again? Would really appreciate your input and sorry if this is in the wrong place.
Love your content and would love to meet up some time. Maybe do some work on our bikes! Once I solve this, I'm ready with my ProCycle Jet kit and everything to do with it.
HI Michael Curtone and thank you for your questions. As I always do Ill point out I am not a mechanic but just a guy that enjoys tinkering but I will give you my thoughts. White smoke for most modern bikes would be a clue you had a head gasket issue and coolant was entering the combustion chamber but as you know the DR650 is air cooled so this is not a possibility.
I do get white smoke occasionally at start up as the bike burns off any condensate that may be trapped in the system from sitting a while however in your case it is after long periods of longer most likely sustained engine speeds on the highway.
Again I am not an expert but I like to start with the simple stuff first.
1. Is the choke sticking or could it be sticking causing a rich condition?
2. Have you cleaned the fuel filter that is in the carburetor intake tube? This is quite small and perhaps you picked up some contamination at some point? This could result in a fuel starvation issue and lean condition.
3. Have you pulled a spark plug to see what it looks like? Although not fool proof, reading the plug can tell you if it is running lean or rich.
I would start there and see what turns up. there are other potential issues but start simple first and see if these produce results.
Also the DRRiders.com is a great resource as well that can help new owners and riders solve issues. there are many much more knowledgeable people there in one place who are more than willing to assist as well.
thanks for the question, and please keep me updated.
Dino
@@DinosTinkerShed Thanks so much for giving such a lengthy and detailed answer. This is why I love your channel.
I just installed my ProCycle Jet Kit today myself and I am NOT a handy man. It was very satisfying and managed to get my bike started successfully, all without completely removing the carburetor.
Right now I'm working on tuning and ran into some issues. Left on a comment/question on your relevant video regarding tuning.
Thanks again.
All hail the great Dino
All hail the great viewers like yourself, you make it happen!!!!
Dino
Well you have fun then. Good on you.
Excellent Dino! Thanks again for this great video! Always a pleasure to learn from you!
My pleasure!
Dino
Dino, this is a well detailed and informative video. All the steps required are well explained and filmed. This video will be a great help for all who want to replace fork seals. Handlebars- I went for a 50mm (2") height increase. This is a great help with head position when standing on the pegs. Seating is a little more upright but as you have a screen (as I do) you are still protected. Thankyou
Thank you Mal, did you use risers or a 2" rise bar?
Dino
@@DinosTinkerShed Dino I went for a new bar. Bit of a job getting the hand grips off and onto the new bar. There are some good riser blocks available now and the job would be easier with those. M
Dino, once again another fantastic video. Looking forward to the next one. I rebuilt the fork over the winter and luckily the bushings were still in ok shape. Brapp!
Great video.
Selling mech is a good idea.
Thank you for the feedback Duane.
Dino
good video dino, keep it up i love it i’ve been watching all of your episodes . your instructions are very simple and straight forward you are a blessing to the motorcycle community. ride safe out there and grab your self something warm to drink !!
I am very glad you are enjoying the content and thank you for the feedback and kind words. I'm enjoying a coffee as I type 😉.
thank you again
Dino
You deserve way more subscribers! Great video as always.
Thank you, glad you enjoyed it.
Dino
Dino, are you planning on doing a DR vid on greasing the rear suspension pivot linkages in the near future??? That would be interesting.
I am but it will not be until the winter here, I am having too much fun riding right now. Thanks for the question.
Dino
Hi Dino. Im doing a review of your videos and finding several are very informative.
I did a front and rear suspension upgrade almost as soon as i purchased my bike using Cogent shocks, front springs and emulators. I also lowered the bike because although Im close to 6 ft tall i have a pretty bad left knee. . 😢
Looking at those forks they have definitely had work . That spacer is much longer which will have reduced sag plus that spring is very probably stiffer. I say this because Im about your weight and I promise you the standard Suzuki setup would have you almost scraping your nose on the ground with full braking. The front end is super soft.
One other thought is that when i take of the front wheel I always fold a piece of cardboard and jam it between the disc pads to keep them apart. This is so a friendly " helper" doesnt squeese the brake lever, pushing the pads out and spewing brake fluid everywhere.
Dont ask why I know this. 😢
Thank you John, it's nice to get some confirmation on my spacers. I suspected they were replaced and they do help a lot for sure. Please keep up the great feedback.
Dino
once again another 10/10, top quality!
I have a 2020 DR650, few months ago I put new springs and the cogent DDC's into my forks. We measured the fork oil going in to the MM. And then, just because my Dad is a perfectionist, he rigged up a jig with a straight tube cut to the exact level the oil should be at with a big-assed horse syringe on the end of it... and it was perfect. If you get the right amount of oil, measuring is redundant.
Thank you for the information, its good to know that the volume they state is the right amount when measured, great information to have, also it sounds like your Dad it my kind of guy, precise and inventive!
Thank you for taking the time to comment
Dino
Great video Dino!
Nice video Dino, very informative..
Glad you liked it!
Dino
I haven’t watched it yet Dino, just skimmed through, but it looks like another fantastic video. I love your style of videos, they are the best I’ve come across on TH-cam for DR650 maintenance and general DIY stuff.
I had a fork seal leak on my 2017 DR650 recently, but luckily was able to fix it by running a home made “seal mate” from a plastic bottle around the seal, which must have removed a bit of dirt causing the leak. I thought I lost heaps of oil as the engine and my boots were covered in it. To judge how much oil to top up I used a dipstick made from a long stick and compared oil levels with the fork on the other side. Surprisingly only had to add about 150 ml.
I will refer to your video again if I ever have to replace my seals.
Wow, thank you so much for the feedback, it lets me know the content I'm creating is resonating with viewer. I am glad you find the videos useful and I should really make a follow up video about your seal saver trick, I've never done that myself but I have read it works well.
Thank you again for the comment, it is appreciated.
Dino
The quality of your videos are amazing and I hope they get out to more viewers. Maybe the seal mate trick could have solved your leak too?? Anyhow, I’m really glad you made the video for reference.
When I noticed my leak during a ride a friend had a seal mate on him which I used but it didn’t solve the issue. When I got home I watched a couple of TH-cam videos about using them and learnt that first I should have removed the dust seal. Obvious now, but I had zero experience with forks so didn’t have a clue, After doing this and trying again with my seal mate made from a plastic bottle it worked.
Came here to prep for putting in the cogent spring and ddc kit
Hey thank you for the comment, I hope it was helpful.
Dino
This helps me a lot thanks 😎👍
Excellent video!!
Glad you liked it!
Dino
I can usually fix my leaks by running a feeler gauge under and around the seal, more often than not it's just a bit of dirt on my bikes. Someone made a special tool for that.
I have read about doing this, some say a piece of a one gallon milk jug works as well. I have never tried it myself but it does make sense. Thank you for sharing the tip.
Dino
@@DinosTinkerShed sure, good video, you are my DR 650s manual😁
I had pro taper pro handle bars on my YZs with a riser and really liked them
Pro taper seems to be the bar most recommend. Maybe we should take a trip to royal someday 😉?
Dino
The rear lower for the dr650 also has a section that needs to be flipped on the shock.
Thank you for the correction. 😀
Dino
Okay I would need an instruction video on lowering the Dr's suspension properly, or alternately to raise the suspension back to normal from a bike that had been lowered.
Go ahead for merchandise! 👍👍
Thank you for the feed back.
Dino
Your videos are amazing, thanks for sharing Dino!
On my DR650, I just finished installing a set of ProTaper Adventure bars using the ProTaper universal rubber adapter. I had to drill out the OEM bushings, but it went on pretty easily. It seems like a nice clean installation (fat bars with no adapters), and just about the perfect height (for me), but I haven't had a chance to put more than about 200km on it since the mod, so time will tell.
Thanks for the information on the bars, I've looked at the ProTaper adventure bars and they look very good.
Thank you again
Dino
hey dino great video thanks mate. safe riding mate.
Glad you enjoyed it, same to you😁
Thanks for the comment
Dino
Nice job.
Thanks!
Dino
Just picked up a new DR. Been watching your videos. Sell some merchandise. I'd buy a tee shirt and cap to support your great videos. Bob in Louisiana.
So glad you enjoy the content. I was selling shirts for a while but I was using drop shipping through etsy, once they take their cut you basically sell them to support the shipper 😖. I think I would need to buy bulk and ship from home, which at this time I really do not have the time to do.
Thank you so much for the support though, it is awesome.
Dino
Well done
Great video as always Dino. I'd highly recommend the Acerbis noeprene fork protectors. As opposed to the plastic gators, they don't have holes where dust and mud can be sucked in on extension. 30000km on my DR and forks are still bone dry and it's not had an easy life (wheelies, offroading, jumps, rough roads, etc)
Great informative clip.!! As for the handlebar upgrade, I would suggest just an Alloy 7/8 -22mm upgrade. There is many bends available, but ProTaper is my pick for branding and durability. Cheers..
Thank you for the feed back and the Pro tapper suggestion.
Dino
That was great!
A good way to get the word out about you and your channel would be to have your loyal followers wear some fancy t-shirts and promote more subscribers. Put me down for an XL if you decide to go that way!
Thank you for the support! Ill get to work on it.
Dino
Thanks for the great video. I am the new owner of a 2008 DR 650 with 14k miles. It seems to be in good shape but I'm going through it to get to know it better. Was hoping to get to the fork seals and bushings this weekend but shipping delays has me waiting. It'll be interesting to find what changes the previous owner made to the front suspension, there's something different in there. I'm hoping for DDCs.
Excelent
Excellent video Dino. Using this video allowed me to replace a leaking fork seal on my might DR650. Have you upgraded your front fork yet?
Thank you for the comment and I am glad you found this video useful. I have now yet upgraded the fork, it is not on the top on my list right now but if and when I do I will show what I do.
Thank you again
Dino
D'Oh!!
The nice thing about leaking fork seals is after a week or two it stops forever.
That is very true lol
Dino
Well done , you explained that well. I dont know why they dont put drain screws on the tubes. I would change oil more frequently if they did. Its a bit of a hassle to pull the tubes just to swap oil out. What were they thinking? Or perhaps they were cutting costs. Who knows.
I'm not sure why they don't, they may want to force you to take the forks apart to inspect the internals, not really sure.
Thank you fort the post.
Dino
Re filling the oil might be a bit tough. There would be alot of air left inside wouldn't there?
Because you still have to pump the tube to get all the air out, which you cant really do with them installed. Takes like 20 minutes to remove the forks, it's not much work considering you dont have to do this often at all.
Hello Dino from Cloverdale California.
Wondered what type of tires do you run on your DR?
I appreciate your video presentations on DIY - DR projects. Very clear and well done!
Hi Geoff, and thank you for the question. Right now I have Kenda tires on the DR, a 54H on the front and a 64H on the rear. however the front is at the end of its life and I will be changing these out soon to set of Shinko 705's. The Kenda's have been good tires but I got a good deal on the Shinko's so I thought I would give them a try next.
Again thank you for the question and thank you for the comment.
Dino
Way better to measure the fork oil height, there could still be oil left in the fork that you couldn't get out and just filling it by volume would mean there's then too much oil in there.
This is a true point especially if you are not dismantling the fork completely as I did in the video.
Thank you for the comment
Dino
This great im about to do my forks i also bought bushing kit but cant find much info on replacing them especially the small black orings it comes with where do they go?
ProTaper CR High
Thank you for the feedback.
Dino
Cheers from Saskatchewan! I found your channel while I was looking for videos on maintaining my DR650. I just wanted to say thanks; not only have I gotten lots of information on maintenance but I got a lot of confidence to tinker with my bike. I even decided to expand my tool sets and do some work myself that I thought I needed to pay a shop to do. So, I have replaced all my springs with racetech stiffer ones (the back SUCKED BTW), added intiminators in the forks, and added a screen and tank. And I replaced my bent handlebars with a Protaper bar.
Have you given any thought to changing your carb by any chance? I have a TM-42 and the conversion parts from Australia to go to the pumper carb from the CV carb, and I was wondering if you'd thought of doing one of the flatside carbs in the future. Apparently it can give slight increase in MPG in addition to the throttle response improvements.
Hey thank you for the feedback, I am glad you find the content helpful enough to tackle some of the work on your DR yourself. Again I am not a mechanic but I find it fun to tackle some of these jobs on my own as you are and you learn allot along the way. 😀
I have looked at the TM-42 but at this point I don't plan on upgrading to it. After the Jet kit upgrade on my BST I find it performs fine for the riding I do and seems to start and idle much better now that I was able to adjust the air mixture screw. From what I have read the TM does improve the bike in the areas you mentioned however It is a costly upgrade for me considering I find the current performance of the bike satisfactory for my riding style.
However If someday I get a good deal on a TM I may choose to upgrade and at that time I would definitely make a video on the process.
Thank you again for taking the time to comment and aske a question.
Dino
Dino thanks for all your videos lm 52 years old but my dr 650 2024 turn me 25 years old l got the bike cause l use it like my daily driver to go to work crosing the border from Tijuana MEXICO to san diego california USA monday to friday adding 44 miles day by day Do you think that is ok to do my oil changes every 2500 miles? to my understanding its every 3000 miles but l want to care the DR very good also l never use it for dirty roads only for freeway and my speed always its 80 miles per hour its not bad for this kind of motorcycles? Well for now its all, Thank you again for everthing.
Hey, thank you for the question, I'm sure that 300 miles is fine but if it were me I would do what you mentioned and change it at 2500 miles. Oil and a filter is not to expensive and with all the higher revving riding on the freeway I think a little prevention is a good idea.
Question: where can i order that service manual you showed? thanks 🙏🏽
Great question the clymers manual is avalable on Amazon at least here in Canada it is. Hope this helps, thanks for the question
Dino
Hey dino i changed out my fork seals a while back and made sure to do everything right but when i sit on the bike and my weight puts load on the suspension the front drops and extra inch or two and im not sure why that is. Is it because i didnt cycle the fluid and get the air all out? I made sure to measure the correct amount im not sure if it can cause some damage but ive been dealing with it for the season but since winter is coming i was thinking about doing somerhing about it. Any input? Thanks!
Sorry for the late response on this. again I am not an expert on this but my understanding is that the spring set your ride height not the oil (it dampens the action of the fork). My first thought would be that you may have installed the spacer on the wrong end of the fork, effectively lowering the bike. I know it is a pain but I would say you ma need to disassemble and check the order of your installation. :(
Dino
@@DinosTinkerShed well besides not getting all the air out of the forks im not sure what it could be i have the spring then plastic spacer then metal washer on top then fork cap.
Any negative effects from having the forks like this?
So, were the springs stock?
Hello Dino .... Can I have your email ?
Want to share some pictures of My DR.
Hi Pedro, my youtube E-mail in on my you tube channel home page in the about tab.
Dino