Front fork problem

steadyroller · 05-19-2014, 10:09 AM

My son has a Suzuki GZ250 that he purchased last year as a learner bike with the intention of upgrading some time down the road. Unfortunately he lost his only key back in the winter and had to remove the key switch to have another key made by a locksmith. Here's the problem: when he was removing the handlebars to get to the key switch (mounted under the handlebars), he inadvertently removed the upper dust caps from the front suspension forks thinking they somehow help the handlebars in place. Well, when he did that, the spring pushed the inner tubes up out of the forks. We tried yesterday to push the inner tube down and replace the dust caps, but the spring is just too strong. Will the forks have to be removed to get them reassembled? If we jack up the front of the bike from the frame, will this take enough pressure off the forks to replace the dust caps?

Thanks

**jonathan180iq** · 05-19-2014, 11:08 AM

I don't know how he removed the top cops with the bike on the ground, honestly. I've done spring replacements on several different bikes and taking the load off of the front of the bike is the first step. Did he do both at the same time? I've always done one side and then the other.

I've not done it on the GZ, but find a stable place on the frame under the motor and lift the bike just enough for ground clearance. The tire should spin freely. You don't have to life it 3 feet in the air or anything. That will sink you spring stops enough to at least help. You're still going to have to work those mothers back in there if you're doing it by hand. (The GZ might have bolt tops, which would make it easier. My ninja had simply a pressure spring and you had to compress the springs while installed the circlip by hand and hoping to god it didn't come back and blow out the top of your skull...scary stuff.)

Refer to this parts diagram for some help.
http://www.ronayers.com/FRONT-FORK--C227952.aspx

05-19-2014, 10:09 AM	#1
steadyroller Junior Member Join Date: May 2014 Posts: 3	Front fork problem My son has a Suzuki GZ250 that he purchased last year as a learner bike with the intention of upgrading some time down the road. Unfortunately he lost his only key back in the winter and had to remove the key switch to have another key made by a locksmith. Here's the problem: when he was removing the handlebars to get to the key switch (mounted under the handlebars), he inadvertently removed the upper dust caps from the front suspension forks thinking they somehow help the handlebars in place. Well, when he did that, the spring pushed the inner tubes up out of the forks. We tried yesterday to push the inner tube down and replace the dust caps, but the spring is just too strong. Will the forks have to be removed to get them reassembled? If we jack up the front of the bike from the frame, will this take enough pressure off the forks to replace the dust caps? Thanks Login or Register to Remove Ads
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05-19-2014, 11:08 AM	#2
jonathan180iq Super Moderator Join Date: Jan 2007 Location: Dalton, GA Posts: 3,996	I don't know how he removed the top cops with the bike on the ground, honestly. I've done spring replacements on several different bikes and taking the load off of the front of the bike is the first step. Did he do both at the same time? I've always done one side and then the other. I've not done it on the GZ, but find a stable place on the frame under the motor and lift the bike just enough for ground clearance. The tire should spin freely. You don't have to life it 3 feet in the air or anything. That will sink you spring stops enough to at least help. You're still going to have to work those mothers back in there if you're doing it by hand. (The GZ might have bolt tops, which would make it easier. My ninja had simply a pressure spring and you had to compress the springs while installed the circlip by hand and hoping to god it didn't come back and blow out the top of your skull...scary stuff.) Refer to this parts diagram for some help. http://www.ronayers.com/FRONT-FORK--C227952.aspx
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