Front Fork disassembly Aquila GV650
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Bike Model = : Aquila GV650
Hi folks.
I am pretty good at following workshop manuals, but I am a bit stumped as the information given in the GV650 manual is, at best, sparse. So, front fork disassembly has gone well up to page ‘Chassis 7-22’ (see post below) where at the top it says ‘Remove the outer tube (1) from the inner tube.’ without any further guidance on how to achieve that. If by that it means slide the outer casing off the hard chromed forks (I question because the photo doesn’t really look like the anodised aluminium outer casing tube) then I have a problem because the outer casing slides to the end of the chrome fork tubes and comes to a metallic hard stop. Now I have seen some videos (of other bike brands) where at this point the person demonstrating repeatedly slams the tube to the end of the fork as it is the seal holding the two tubes together, but as I say, it feels like a metallic stop not that of the shaft hitting the rubber seal, and I don’t fancy forcing it. To add confusion, on the next page (7-23) it says ‘Remove the dust seal (1) and the oil seal stopper ring.’ but it shows a photo of the outer tube and fork tube still together. Then it says to remove the oil seal with special tool 09913-50121 (also a Suzuki tool). I’ve had a look at that tool and it is only for use where the inner and outer tubes are separated, and yet in the photo above they are together!!
Given that the chrome fork tubes rust and rip the seals this must be a fairly common job, so can anyone help me separate the two tubes please?
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<video controls=”controls” width=”300″ height=”150″>
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Thanks for the dropbox link, i can see what’s happening there, but i could not tell if the later forks have a permanent retainer there or not but i suspect , they made a slight error on the document about what tools to use. Is there a CIRCLIP inside that’s holding the stoppers or is it threaded inside ? Like how a sportsbike has a mono shock with threads for 2 locking adjusters to stop the spring shooting forward & for adjustment.
if not, is there a big BOLT under the fork , to undo it ? , that may separate the chrome tubing from the caliper mount – Not all Hyos have this bolt but worth checking.
Also, if it helps,. have a look at older videos of the SV650 and older Suzuki GSXR bikes, they used the same KYB forks as Hyosung does. Both of them still use KYB forks to this day but they have gone through many variations! – Try 1990s SV and GSX videos , and see how they took it apart , i could not locate a picture of separating the two tubes on your GV. As frustrating as it sounds, I love fixing the hyosungs but forks are the most annoying part of the job!
// Meditation doesn't mean you have to sit still....
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I have found that this video by ‘Delboy’s Garage’: (14) Delboy’s Garage, USD Fork Seal Replacement – YouTube (Delboy’s Garage, USD Fork Seal Replacement) was very helpful. It is clear that the manual is either just plan wrong, or was written for a different version (although mine is an earlier carburettor model). I have followed the method used by ‘Delboy’ and it has worked. You do not need the special tool mentioned in the manual (09913-50121) as the seal comes out when you separate the two tubes by ‘clonking’ them apart, but you do need a special driver tool to seat the bush and new seal on assembly: Adjustable 39mm-50mm Oil Seals Install Tool Motorcycle Fork Seal Driver Tool | eBay (ebay item no.364565521173). That tool was cheap enough, and I have ordered the correct oil. Although this would be a very niche audience to play to, as the manual is misleading I am making a video which I will publish on YouTube for the guidance of other members and I will rewrite the chapter with the correct method. Please check back here in a week or so.
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