MY "trick" on the plastic spacers
I simply drill a second pair of holes with a diameter of 8 mm, about 10 mm above and twisted 90 ° to the existing ones, i.e. towards the open end of the sleeve
Tool for this?
Stand drill with 8 drill and holder on the table of the drill.
I cautiously clamp the sleeve into it and also drill the two holes very carefully, because if the drill tilts only minimally, it virtually pulls the sleeve out of the clamping and the sleeve tears, in the worst case it even breaks.
Then ordering a new part is inevitable and the Busa stands still / is definitely "set off" for at least a week,
because THIS thing does not even have my very well-stocked dealer in stock.
A crack could possibly be secured by means of the "pot" washer and the fork could be reassembled, but that is not really nice and I do not know any possible consequences at the moment.
Once I was allowed to order a new one for around € 17 / pc.
(By the way - because the Gen II plastic spacer can
tear / burst as soon as tool # 1 is pulled down,
screwing is required here.
And if it really shits, the new spacer has to come from Japan and this can quickly take 2-3 weeks.
MEEEGA not funny!
But what is the reason for my drilling?
Quite simply - this way I get the spacer pushed in further using tool # 1 and have zero stress to insert the Gen I tool # 4, because the sheet, which is only 1 mm thick, does not really inspire confidence because it simply bends and I the strong one Presumption is that something will slip.
Then, when I finally had the fork apart, I carefully worked this plastic spacer with the drill press and an 8-bit drill before doing any other work.
Because caution when clamping and drilling is the order of the day - the plastic is not very stable and one does not watch out hellishly, the drill clamps, the part slips out of the clamp and Tears!
Already happened to me and relatively expensive - the stupid thing costs, depending on where you order it, around 17-22 €.
And even my really well-stocked dealer does NOT have these parts in stock.
(This photo shows a pipe clamp made of cast material from the USA - not available in Germany)
The distance "a" is approx. 8-10 mm and the diameter Ø of the hole is 8 mm.
As a result, the holder sits higher by this distance "a", the spacer is pressed further down and the plate for the Gen1 suddenly fits perfectly between them.
Bingo - no more stress in the future.
Because every 25,000 km or at least every 4 years the fork oil should be replaced and then the work is a lot easier, moreover I don't really trust a 1.5 mm thick aluminum sheet and at least my Gen1 - Bracket is so fat and stable that I definitely don't have to worry about it.
Then the thought arose to use the "Alu Spacer" of the Gen1,
but none - the thing just doesn't fit.
So you have to stick to Gen2 plastic first.
additional info :
Gen II spacer (the white piece on pic below) and where it was / is also installed:
Part number / designation of the WHITE piece (spacer)
Brand Orig. Part number Description Price
SUZUKI 51176-40F30-000 Spacer/Spring 15,37€