M109R Fork Seals Replacement

Instructional video on replacing the fork seals and fork oil on a Suzuki M109R. In this case a 2012, but the process is generally the same on all years.

Intro
1. Tools Requires – 1:00
2. Remove Headlight Nacelle - 3:23
a. (2010 and up?) 4x 10mm Bolts, 3 Electrical Connections
3. Remove Fender 6x 4mm Allen head bolts, 3 on each side (careful the brake line brackets) – 4:55 (mistakenly listed as Step 2 again)
4. Remove Front calipers – 5-45
a. 4x 12mm bolts, 2 on each.
b. Use shims to keep pads separated
c. Hang with bungee cords.
5. Remove front Wheel – 7:30 (OK, my title cards got messed up so the step numbers are all off)
a. Loosen Axle pinch bolts
b. 24mm wheel axle tool with breaker bar to undo axle.
c. Pay attention to spacers
6. Remove forks – 10:02
7. Mark on forks where they are in relation to triple tree for future ref, vertically, also measure, should be ~ 5mm from top of triple tree.
8. Fork Disassembly – 13:15
a. Loosen the front fork upper clamp bolt (6mm Allen head)
b. Slightly loosen fork caps 22mm
c. Loosen lower clamp bolts
d. Carefully slide fork out
e. Undo the fork cap and pull it up slightly
f. Use Ratchet Straps and spring compressor tool to compress spring
g. Use a large wrench wrapped in a towel through the caliper mounts to hook one end to, hook other to the compression tool
h. Gradually and evenly tighten the straps till the spacer is below the lock nut
i. Insert the fork damper rod holding tool between the PVC spacer and the lock nut
j. Loosen the lock nut and remove the fork cap (Xmm and 22mm)
k. Remove the damper rod holding tool
l. Carefully loosen / remove ratchet straps and the compression tool
m. Remove spacer and spring
n. Invert fork and pump dampening rod multiple times to facilitate oil drainage
o. Drain oil from forks – Let sit inverted (draining into a pan) for at least 10 – 15 minutes
p. Split forks into two
q. Remove dust cover
r. Remove Snap ring
s. Remove seal and retainer
9. Reassemble forks – 21:16
a. Put fork back together
b. Put New Dust Cover, Seal and retainer on inside fork (If you have seal lube you can use a bit of that on the fork)
c. Put forks back together leaving enough separation to use the slide hammer
d. Use 46/47mm slide hammer to seat seal
e. Reseat clip and dust cover.
f. Screw damper rod holding tool M10 x 1.0 to the damper rod
g. Refill fork with oil, pump damper rod 10 times, watch for bubbles. Repeat until no bubbles
h. Fill back up to top level of outer tube, move outer tube up and down several times till no more bubbles
i. Keep Fork vertical for 5-10 minutes.
j. Set fork oil level to 133mm (5.2) using gauge.
i. Move metal tube through locking ring, use caliper to measure 133mm from ring to tip of tube, set with grub screw.
k. Use plunger to remove oil till it is just below the tip of the tube (you will only suck air).
l. Install spring, tapered side up.
m. Install Spacer
n. Use compressor tool / procedure to replace fork cap
o. Inner lock nut should be tightened to 11 lb-ft.
10. Reinstall forks – Use marks from step 6 to re-orient (Should be ~5mm above steering stem) – 29:06
a. Tighten lower clamp bolts to 16.5 lb-ft
b. Tighten cap bolt to 16.5 lb-ft – recheck height
c. Tighten upper fork clamp bolt to 16.5 lb-ft
11. Replace front wheel (Axle at 72.5 lb-ft, pinch bolts at 16.5 lb-ft) – 32:57
12. Replace front calipers (Bolts at 28.0 lb-ft) – 35:04 - THIS IS MISSTATED in the video as 16 lb-ft
13. Replace fender – 36:54
14. Replace headlight nacelle – 38:50
Finish

46/47mm Slide Hammer (Ringer Fork Seal Driver) -
https://www.amazon.com/Motion-Pro-08-...
Damper Rod Bleed tool - https://www.amazon.com/gp/product/B07...
Fork Oil level tool – https://www.amazon.com/gp/product/B00...
Fork Spring Compressor Kit –
https://www.amazon.com/MOTORCYCLE-FOR...
All Balls Fork Seal Kit -
https://www.amazon.com/gp/product/B01...