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BikeMaster Rebuild: 1980 Suzuki RM100 – The Front Forks

BikeMaster Rebuild: 1980 Suzuki RM100 – The Front Forks
By Steve Mayes October 13, 2017

When working on a 38-year-old motorcycle, there are certain moments that will amaze you. One of those moments came when we disassembled the front forks. It was pretty obvious that they'd never been serviced. If you've ever had the pleasure of smelling the suspension fluid that was used back in the day when this bike was brand new, then you know how nasty the forks can get when they haven’t been serviced. The old fork oil looked like mud.

We decided to take the clear coat off of the front sliders. This was applied at the factory when the bike was brand new and is all old and damaged since the bike had been sitting for so long. We didn’t want to leave the chipped clear coat on our newly rebuilt forks. It took a lot of elbow grease to get off but it was worth the effort.

Once the components were thoroughly cleaned, we added new bushings and BikeMaster fork seals.

As with any project, having the right tools to work with makes the project much easier. We utilized the BikeMaster Shop Vise to make the fork rebuild a breeze.

Now that the forks are installed and the front brake backing plate just needed a good cleaning and new brake shoes from BikeMaster, we're ready to move to the wheels and controls.


The front forks needed some serious TLC.



It looked like the forks had never been serviced.


There's a big difference between the new fork oil and what was drained out of the forks.


The fork components are cleaned and ready to be assembled.



The forks are assembled and ready for installation.



The drum backing plate cleaned and new BikeMaster brake shoes installed.


The forks have been installed and the front end is coming together nicely.


Up Next: Front wheels and controls.