Replacing RGV150 fork seals on the cheap (and manual-less)

[pyrocam]

What I found out (for other searchers)

RGV150 fork seals can be bought from Suzuki (Asia) Via Holeshot on Barry's PT Road in Takapuna (akl) for $22.50 each
the size is 29 41 11

Fork Oil is 180ml of 15 Weight


original post:
my project bike (RGV 150 S 2001) needs new seals but acquiring a manual is impossible.
What tricks and tips should I know before pulling the forks off.

Do I need to measure the old oil?

cheers

[Pedrostt500]

try www.workshopmanuals.co.nz or you could rock into your local Suzuki dealer, find out the parts persons favourite beer and photo copy their manuals relivant pages, when you order the new seals.
you could also check if there is a web site deadicated to your bike that has a tech support section.

[R6_kid]

send it to Robert Taylor

[xwhatsit]

send it to Robert Taylor
For fork seals on a 150? Get off the grass. Just because we're lucky enough to have one of the world's best suspension tuners lurking on our website doesn't mean we need to pay him to do basic maintenance. Seals aren't exactly difficult to do.

@pyrocam: if the seals need doing, then of course (at least some) oil will have leaked out by now. So measuring the oil that comes out is not going to be much help to you. Doing a brief Google search funnily enough only turns up a thread that you posted in back in 2004.

Ask the Suzuki dealership when you buy the new seals. Or post in a Malaysian forum I suppose.

In terms of dismantling the forks, they're just simple normal right-side-up telescopic damper rod forks. About the hardest bit is getting the circlip out from on top of the old seals (solve by getting circlip pliers) and stopping the damper rod bolt from spinning (it comes out underneath the fork) while you undo it. Either get a rattle-gun onto it, or do it the cheap way -- stick a broomstick or something similar down the fork to hold the damper rod in place while you undo the bolt from underneath.

Putting the seal back on, take your new seals to Mitre 10 first and find a bit of PVC pipe the same diameter as the outside of the seals. Buy a length at least as long as the fork stanchions. Use this to drive the seal in evenly when you put them back together.