Author Topic: Front axle wrench size? (Read 5416 times)

todius · « **on:** June 23, 2005, 11:10:51 PM »

Hi,

I went to replace my fork seals today and was quickly stopped by the front axle. I've never seen a bike that uses an allen bolt for the axle.

Needless to say, my allen wrench set stops at 10mm which is not big enough. I couldn't find this in the FAQ and the manual lists a "special tool", so, for those of you who've removed the front wheel, what size allen wrench/hex driver does it take to undo the front axle? Many thanks for your help.

interfuse · « **Reply #1 on:** June 24, 2005, 12:10:10 AM »

Quote from: "todius"

Hi,

I went to replace my fork seals today and was quickly stopped by the front axle. I've never seen a bike that uses an allen bolt for the axle. Needless to say, my allen wrench set stops at 10mm which is not big enough. I couldn't find this in the FAQ and the manual lists a "special tool", so, for those of you who've removed the front wheel, what size allen wrench/hex driver does it take to undo the front axle? Many thanks for your help.

The front axle is 12 mm.

The fun starts when you need special tool "G" to undo the guts of the forks. It's a hex head thats either 28, 29, or 30 mm. The tool from suzuki does those 3 sizes but I can't remember what end of the tool fits the forks.

todius · « **Reply #2 on:** June 27, 2005, 02:22:07 AM »

Thanks for the info.

I picked up a 12mm hex driver and managed to change the seals this weekend. Lucked out on removing the damper rod. I've held the rod in other bikes using a wooden dowel... didn't have one on hand so I tried the handle that goes to my hydraulic jack... a perfect fit!! The little peg on the end even fit just right in the torx-type head of the damper rod. Just gotta remember that next time.

b4cruz · « **Reply #3 on:** July 02, 2005, 04:43:25 PM »

Quote from: "todius"

Lucked out on removing the damper rod. I've held the rod in other bikes using a wooden dowel... didn't have one on hand so I tried the handle that goes to my hydraulic jack... a perfect fit!!

I have no such luck
i have to go buy the "G" tool
Sudco or Motion Pro Damper Rod Fork Tool for 41C Kayaba
http://www.bikebandit.com/partsbandit/product~pf_id~3279963~dept_id~1215882.asp

were you guys able to get the seals in without the seal drivers?

interfuse · « **Reply #4 on:** July 02, 2005, 05:38:35 PM »

Quote from: "b4cruz"

were you guys able to get the seals in without the seal drivers?

Yes. But it took some detective work. Don't tell my old lady but I ended up cutting part of a vacuum attachement to custom make the seal driver. You just have to find something that fits over the fork leg and into to the outer tube. I then rammed the vacuum attachment with a piece of 2" abs pipe until the seals popped in.

I'm not sure if it's the best way but it worked.

todius · « **Reply #5 on:** July 08, 2005, 05:33:23 PM »

I drove the seals in using a piece of 2" Sch40 PVC pipe. I placed the old seal on top of the new seal to act as a cushion while I drove it in with a hammer.

interfuse · « **Reply #6 on:** July 08, 2005, 06:33:37 PM »

Quote from: "todius"

I drove the seals in using a piece of 2" Sch40 PVC pipe. I placed the old seal on top of the new seal to act as a cushion while I drove it in with a hammer.

Great idea. I'll keep that in mind for next time.

b4cruz · « **Reply #7 on:** July 12, 2005, 02:57:06 AM »

17mm outer
11mm inner
oil seal copper crush washer/gasket for damper bolt

On GS500, B600 & B400
Kabaya 41 fork conventional (right side up)
damper bolt 51147-16510
damper crush washer/gasket 51148-41310
OIL LOCK PIECE 51195-06C00 (except) GS500
Top Cap 51351-10D00 but the cap O-rings are different?
cap & o-ring completely different on GS500

so gives these part #s @ the parts counter
and if they don't have them ask them to
try the other suzuki bikes

Krautwagen · « **Reply #8 on:** July 13, 2005, 02:07:56 AM »

I just did seals tonight too...

The 'easy' way to get the inner's out is to hit the bottom 8mm allen with the good 'ol impact gun. Then just use a dull drift (i.e. 1/4" socket extension) to gently tap the seals in.