82 Fork Parts problem

[johnod]

I'm rebuilding a stock set of forks, (82 1100 Kat) and looking to order some new slider bushings/ anti friction rings/ slide metal, or what ever you choose to call it.

However looking in the manual, or online parts fiche, there appears to be no upper part, just the lower part on the stanchion,is that possible?
It sure looks like it has an old part in there to me.

Anyone encounter this before, or have an answer?

Thanks.

[Kreylyn]

I'm rebuilding a stock set of forks, (82 1100 Kat) and looking to order some new slider bushings/ anti friction rings/ slide metal, or what ever you choose to call it.

However looking in the manual, or online parts fiche, there appears to be no upper part, just the lower part on the stanchion,is that possible?
It sure looks like it has an old part in there to me.

Anyone encounter this before, or have an answer?

Thanks.

I'm not nearly as familiar with the older than 88 models, but...

A glance at some of the parts fiche shows to me the call one part a Metal Slide and another part "Free Piston"... both look like the parts your asking about. Check your fiche again?

Krey

[johnod]

This is the Alpha part fiche site, check 82 1100 Kat.

http://www.alpha-sports.com/suzuki_parts.htm

Piston is part number 7, that's the lower bit, if you find the other bit, please let me know, and I'll owe you a beer.




By the way 8 is not it, that is essentially a spacer.

[Suzuki_dog]

I just rebuilt my forks, the parts diagram is correct with the forks I have. I'm not sure what upper part you are talking about, something that was in your forks when you took them apart? Sometimes guys will shim the top of the springs at the piston (#8) with a metal sleeve or PVC sleeve to help adjust the ride, maybe it was a "shim"? Not sure, do you have pics?

[sixdog]

I just rebuilt my forks, the parts diagram is correct with the forks I have. I'm not sure what upper part you are talking about, something that was in your forks when you took them apart? Sometimes guys will shim the top of the springs at the piston (#8) with a metal sleeve or PVC sleeve to help adjust the ride, maybe it was a "shim"? Not sure, do you have pics?

Agree with Joe. My Katana had a aluminum sleeve the previous owner had installed.

[Suzuki_dog]

If you are rebuilding the forks, I suggest Progressive springs. Around $80 for the pair, but worth it. The originals were stiff.

[johnod]

I just rebuilt my forks, the parts diagram is correct with the forks I have. I'm not sure what upper part you are talking about, something that was in your forks when you took them apart? Sometimes guys will shim the top of the springs at the piston (#8) with a metal sleeve or PVC sleeve to help adjust the ride, maybe it was a "shim"? Not sure, do you have pics?

If you go to the alpha parts fiche above , bring up 1982 GS1100EZ, ES front damper.


You'll see part 10, which the Kat has, now look at part 8, that is basically the same as 10, except it's pressed into the lower leg, and the stanchion slides up and down in that.
So the stanchion doesn't wear on the lower leg itself.
Most forks I've worked on are similar.
The Kat doesn't have that a replaceable part apparently.

If you are rebuilding the forks, I suggest Progressive springs. Around $80 for the pair, but worth it. The originals were stiff.

Ya they are incredibly stiff, did the progressive springs fix that?

[Suzuki_dog]

If you go to the alpha parts fiche above , bring up 1982 GS1100EZ, ES front damper.


You'll see part 10, which the Kat has, now look at part 8, that is basically the same as 10, except it's pressed into the lower leg, and the stanchion slides up and down in that.
So the stanchion doesn't wear on the lower leg itself.
Most forks I've worked on are similar.
The Kat doesn't have that a replaceable part apparently.





Ya they are incredibly stiff, did the progressive springs fix that?

The '82 GS1100EZ ES is not the Katana. Look on the '82 GS1000SZ parts fiche. They do not have the same forks. I have both bikes, and the forks are different. I think you were looking at the wrong fiche.

Progressive springs helped alot. You will still have to play with the dampening settings, but it will be like night and day.

[Suzuki_dog]

Not meaning to "threadjack", but I have an interesting story on my Katana forks. Last fall the right fork completely failed in the compressed position. I've never seen this, nor has many of my Suzuki friends. Took the fork assembly off to try and pull the upper from the lower sleeve, no luck. Took it to a local bike shop, no luck. It is as if they were welded together. Luckily, I have a friend who "hoards" Suzuki and Katana parts in his attic. I ended up buying his set and rebuilding them to make sure the same thing would not happen, again. I have not had time, yet, but I am going to cut open the old fork and see what's going on inside and maybe figure out why it failed...

I got lucky, these front forks are hard to find, and even harder to find in good condition.

[johnod]

The '82 GS1100EZ ES is not the Katana. Look on the '82 GS1000SZ parts fiche. They do not have the same forks. I have both bikes, and the forks are different. I think you were looking at the wrong fiche.
.

I realize it's not the same bike, you didn't seem to know what I was talking about, I used that to illustrate what it was.

[Suzuki_dog]

I realize it's not the same bike, you didn't seem to know what I was talking about, I used that to illustrate what it was.

OK. I am no help in this conversation. All I can tell you is that the '82 GS1000SZ parts fiche for the front damper that your link shows, matches the parts that are in my front damper on my '82 GS1000SZ. The part that is "extra" that you are referring to should not be in the GS1000SZ forks. Maybe someone has put different forks on your bike?

The link to the '82 GS1100EZ ES that you used for reference does show an additional slide at the top, which is correct for the '82 GS1100EZ.

Without having the forks in front of me or pictures, I would think that:
1. It's a spacer someone put in.
2. They are GS1100EZ forks, or some other forks.