chrisgatguis

Hi Walney, thanks for the reply. I've ran into further trouble... I managed to get the damper rod released okay with the broomstick + Spark plug socket solution.. I've put it all back together but i can't get the top bush back down far enough to give me enough space for the washer and oil seal to move down far enough to put the clip on. I can see the top bush go down and i've applied pressure to it and it does move in slightly but not enough to give me the space. I've tried putting the washer / new seal in, then cushioned by the old oil seal over the top i've tapped it down with a plastic thing (end of a plastic cartridge gun) but still it doesn't move.. any ideas? I'm thinking there is a specialist tool which would just slot over the fork tube enough for a tight fit to push things down? stumped

good call i'll try again in the morning - gettin dark now! And cheers for the response btw appreciate it !

Just chatting to Dan and its quite hard to explain so i'm stickin a couple more pics up of 'the thing' lol... okay this is the one i've taken out already, laid next to the bottom part of the fork roughly where it would be.. This is the end which you get to from the bottom of the fork - allan key job (using bar for leverage) this is the other end which i can see spinning round freely when unscrewing the alan key (i think its called the Damper rod)! This is the device i've created to grip the damper rod from inside the fork its a broom with a spark plug socket on the end. its forced on. Idea being stick this right down the fork to lock into the damper rod from inside.. Still doesn't loosen though so i can only guess my spark plug thing is slipping round!!

Cheers Tim, I've found a socket which is for taking out spark plugs, it has one square end which fits perfect! I think i'll wedge the broom handle on to that (or something like that) and then should have enough force / friction which should help! Cheers i'll let you know the outcome!

yeah it does have a hex head like this: Yeah I kinda see what you're saying so, the extension part of my rachet set and then i'd need like a large bolt or something to fit into it.... but short bolt with nuts on so that i can jam it in the end of the rachet extension .... Just wondering if theres anything i can use to try that.. cheers for the idea!

Hi all, I've ran into a problem with one of my forks. One side has gone totally fine and i'm about to replace the seal and put back together. the other side however i cannot seem to unscrew the damper rod bolt as the damper rod is spinning freely internally. This is happening even if both parts are held still. in the Haynes it suggests compressing the spring (so i put the top bolt back on and tightened it) and forced the tube to compress (as much as i could) and STILL it doesn't slakken the allen key bolt.... I've actually looked down the tube with a torch and its deffinitely freely spinning inside. The Haynes also says to stick a broom handle inside to hopefully contact the damper rod enough to stop it spinning. tried that too. I'm stumped especially seen as the other side is fine. Anyone got any ideas? Cheers Chris

Cheers for the replies, ended up ebaying the fork / dust seals and got juice from Halfords.. I've started the job now and i'm taking photos, hope noone minds me uploading them as i go, it might take me several days though.. Its probably a bit OTT with all the stages but just try and put up with it! Propping her up (didn't know what I was doing) Remove speedo cable Remove two bolts Hang the caliper out the way Remove the wheel / axle / bolt Ready to get forks off

Hi all, I've noticed my farks have oil on them after bouncing the front forks up and down with brake on. I'm going to do them myself (well with my dads help). Just wondered if anyone can recommend somewhere online that i can get the seals from - i've seen them on ebay but i also want fork oil and some other service related bits and peices so getting it all from the same place would be ideal. Also, i've got the Haynes manual and service manual in PDF format for a Suzuki GS 500 E if anyone wants them. Dont know if someone wants to host them or something? Disclaimer: I dont know if giving out the Haynes Manual in PDF is particularly legal

Hi, after my previous thread winging about Hein Gerrick i managed to get what i wanted from elsewhere. HJC IS 16 Helmet: Seems really great tbh the fit is perfect for my fat skull! I've put pics on of the little drop down visor, and also the top of the helmet which shows how the screen is activated (slide the thin plastic bit forward to lower the screen - theres three stages, and then the bigger button make it snap back up out of the way). The breath deflector seem to work pretty good also. although not actually ridden with it yet - waiting till tomorrow on way to work. Blue screen - looks pretty good - will post again once i've tried it to see if it cuts any of the wind out but i like the look of it too. sorry bout all the pics - but i like em

Hi Mr Miller cheers for the info i'll have a ride out one day in the next couple of weeks when the weathers fine.. Not been to thirsk in a while even though i've lived not too far away (in Great Ayton) for ages until just recently lol Cheers Chris

Lol i've just sat for an hour straight searching..... I've gone for it in black instead - its cheaper and much more places seem to have it.. Got it from http://www.sounddistribution.co.uk/main.asp in the end.. Hope the order process goes better this time... cheers for the replies! back to work now :S

theres a few shops close by but I know they dont stock the helmet i want just checking everywhere on the net to see what i can come up with lol... Thing is - thats two things they could have had a sale on.. obviously times aren't so hard after all...

Starting to get annoyed now.. I'm probably just over reacting but HG are being a bit cra p.. I've tried buying a fly screen from them, order was placed last week. about 4 days later i get an email saying that my order is being processed. then two days later another saying that it has been cancelled because they are out of stock. The email was literally "sorry this item is out of stock"... I would of expected them to at least offer an alternative product / tell me when it was going to arrive in stock. Inbetween that one i went down to the local HG and looked at a HJC helmet. They never had a XL in stock but the guy said that 'they are expecting an order within the next week'... I gave him my number and told him to ring. So a week has passed and still no phone call (although i did ring him back on Tuesday but still no idea of when the delivery would get in).. So i thought i may aswell order off their website.... placed the order and about 4 days later i've got an email saying "Hi, unfortunately your card was not authorised for the above amount so the order has been cancelled." I dont see how as it was on my credit card (currently zero balance outstanding, oh and you can't use debit cards on their website ).... I wonder if they're trying to fob me off without saying that a second product is out of stock... anyone else dis-like their website? am i over reacting?

Over to one of the more experienced guys i think. It just sounds like that's happening to me

could be your clutch is slipping?

is it only in very wet weather? might be water / damp cocking the spark up..

I've been down to HG today and have asked him to get this in in XL.. I've tried on a few other HJC XL helmets and they all seem the same fit so i'm going to see if i can find it cheaper online. I really want the blue one though and that websites only got it in black / white - annoying because i quite fancied that free bag now that i've seen it lol..

went to look for one of these in the Middlesbrough lidl today - they had sold out of pretty much everything but they did have some rider to pillion intercom's for £5.99 i didn't get one but thought some ppl might fancy one so just so you know.

Thanks a lot for your replies Frankie i've had a good look into what i'd need. At that point I thought damn its going to cost probably half of what the bikes worth to do so i've decided i'll have to let it pass. you never know i might get a new bike later in the year... for now i've ordered a little screen instead lol.. I found that the actual fairing wasn't that bad - a couple of sellers on ebay had them for about 40 -50 quid per peice (2 x side, 1 x top) but then realised i'd need the massive bracket which it connects with (possibly two), new screen, new headlight so i think its a bit too much to do to my 8 yr old bike.. hopefully the thread wont go to waste though as i'm sure someone else will search for it in the future! cheers Chris

wow thanks for that very useful! I've attached a comparison between that one / mine.... What do risors look like? i presume they aren't what mine has already (circled in picture).. One more question.. is the headlight unit for the GS500F interchangable with any other Suzuki's? Gsxr etc? Might make tracking them down a bit easier.. Thanks! Chris

the only difference? i've seen a few aftermarket fairings for 'em which require you to fit a different set of handle bars to allow it to fit. if its a straight swap i might just get it all and try it.

Hi all, has anyone converted a Suzuki GS500E to 'F' before? I've spotted the side fairings for sale and i've contacting the seller about the top fairing. Does anyone know if the bars or anything needs to be modified for the conversion. Also was thinking about the clocks on the 'E' are double pod type, is there any GS500F owners out there who can tell me what their clocks are like? i.e. integrated into the top fairing or just the double pod type same as mine? I'm missing the protection i used to get on my CBR 125 (lol) from the wind etc and was heading down the track of getting a fly screen etc etc.. just thought this might be a viable option. Cheers Chris

Live in Marton myself, originally a Guisborough lad

Hi all, just wondered if anyone knows of a good high vis outer skin i can wear over my textile jacket. I'm after a thin one which isn't restrictive at all but still waterproof.. The one i've got now is a bit on the small size and very padded making it a bit restrictive to ride in.. any ideas? cheers Chris

try swapping the side that works for the other side to rule out your bulbs.