Two questions

[Disaster Area]

Firstly, can anyone tell me the dimensions/characteristics of the front fork oil and dust seals for an 1100GS? I'd like to swap them over and it's probably going to be easier, cheaper and quicker to see if I can get them from a retailer here than order them from the UK.

Secondly, as the final drive oil filler cap has rounded off, does anyone have any advice on drilling it out? I can't remember when the final drive oil was last changed - mainly because the filler cap has rounded off!

Thanks in advance.

 

[Ian J Hartley]

Firstly, can anyone tell me the dimensions/characteristics of the front fork oil and dust seals for an 1100GS? I'd like to swap them over and it's probably going to be easier, cheaper and quicker to see if I can get them from a retailer here than order them from the UK.

Secondly, as the final drive oil filler cap has rounded off, does anyone have any advice on drilling it out? I can't remember when the final drive oil was last changed - mainly because the filler cap has rounded off!


Thanks in advance.

Can’t help you with the fork seals, as that will be stamped on the actual seals themselves.

However, your final drive problem is not the end of the world. You don’t need to remove the fill plug, just drain the oil through the drain plug and fill a measured quantity through the vent. It’s slow, but then if you’re doing your own servicing, times not a problem.

I’m assuming you don’t have ABS, in which case through the ABS sensor hole would be quicker.

 

[Mzokk]

Have a wee look at this thread.

https://www.ukgser.com/forums/showthread.php/40372-Fork-Oil!

The fork seals are 35x48x11 and the dust seal is 35x48x12.5.

With regard to the final drive. The filler bung sits proud of the final drive case. I would cut a slot in it with a dremel, heat it, and try to (gently) tap it anti-clockwise before I resorted to drilling it out.

Just had a look at that old thread.....2005 was the last time I changed the fork oil....when the bike was 3 I've changed one fork seal since then using the quick method. Should probably empty out whats in there and put new stuff in, I'm sure there is some dirt in there by now!!

When I changed the fork oil I put some 10wt in the stuff I poured out looked OK. It was just my first bike with telelever and I would change damping oil in conventional forks ever 2 or 3 years.

 

[Ian J Hartley]

Sometimes a torx bit hammered into a rounded Hex hole can get sufficient grip to work.

 

[Paul Young]

Sometimes a torx bit hammered into a rounded Hex hole can get sufficient grip to work.

This is what I’d try first, then the Dremel a slot/heat and use an impact driver method...

 

[fizzer]

if all else fails to get the filler plug out,weld a nut onto it,if using a mig disconnect the battery first

 

[West coast gser]

Firstly, can anyone tell me the dimensions/characteristics of the front fork oil and dust seals for an 1100GS? I'd like to swap them over and it's probably going to be easier, cheaper and quicker to see if I can get them from a retailer here than order them from the UK.

Secondly, as the final drive oil filler cap has rounded off, does anyone have any advice on drilling it out? I can't remember when the final drive oil was last changed - mainly because the filler cap has rounded off!

Thanks in advance.

1 min google search came up with this from ADVrider.com

Fork Seals 35mm x 48mm x 11mm - Honda Kawasaki Suzuki Yamaha (and BMW R1100GS)
KS16-1020

 

[Posh Pete]

if all else fails to get the filler plug out,weld a nut onto it,if using a mig disconnect the battery first

Or file a couple of flats and get a spanner on it? Alternatively, heat up a socket slightly smaller than the hex and hammer it on?

 

[theoneandonly]

Sometimes a torx bit hammered into a rounded Hex hole can get sufficient grip to work.

2nded , but CAREFULLY , and not too hard. grind a bit off the torx to make it taper.

or chisel it off from the edge radially ,ie horizontally .little bit at a time.

 

[g.s.john]

Before you go attacking the fill plug with a dremel ect get some coarse valve grinding paste dip the appropriate allen key in it and try that.

 

[Disaster Area]

Gotcha!

After a good blast with a heat gun and a few minutes persuasion with a cold chisel and lump hammer, I got the thing out.

Many thanks for the advice!

 

[Mzokk]

Good man yourself