Great Stuff John - saved, printed out and kept -

Well I cant post all the pics since There is a limit on how many you can have per post... Set to 8... If someone can help I will change the codes to show all the pics...

John

Here it is everyone.. Read everything before you do it, and it isnt my fault if you mess something up... images/icons/grin.gif This was done with a 99 750 and it may be a bit different on other bikes.


Remove front fender
(4) 4mm alan head bolts
(2) Pop clips on the brake line
(1) Phillips head screw (with a nut on the back)

If you have a triple clamp lift, remove the damper with a 6mm Alan head

Remove the brake calipers (2) 12mm bolts for each side

Loosen the pinch bolts on the left side (left when facing the bike), 12mm

Loosen the axel 27mm

Loosen the right side pinch bolts

Lift front of bike and Remove front wheel

Take note of how high the fork is in the triple clamp, Stock is 2mm from the top triple clamp to the bottom of the fork cap.

Loosen the fork caps
http://gsxr-freak.gixxer.com/MVC-003.JPG

Take note of how many bars your preload is set to

Loosen the pinch bolts on the triple clamps (there are two on top and two on bottom)
The top ones come off faster if you use the 6" extension and the 12mm socket
The bottom is easy with the 12mm wrench
http://gsxr-freak.gixxer.com/MVC-004.JPG

With a twisting motion, slide the forks down and out of the triple tree

Hold the outer fork tube and loosen the fork cap until the outer tube is separated and slide the outer tube down
http://gsxr-freak.gixxer.com/MVC-005.JPG

Remove the preload retainer clip
http://gsxr-freak.gixxer.com/MVC-007.JPG

Holding the fork cap, remove the preload adjuster

Push down the spring to show a 17mm nut on the center (damper) rod and put the 17mm wrench on it (this is when a friend comes in really handy if you dont have the tool for it, Have them compress the spacer and you put on the wench). To make this faster, there is a washer just above the plastic spacer on the top of the spring spacer, Try to get the wrench between the spacer and washer

http://gsxr-freak.gixxer.com/MVC-008.JPG

Hold the 17mm and spin the fork cap off

Remove the washer, plastic spacer, the spring spacer, and the spring (if your spring is stock take note of the top)

Drain the oil out of the fork by tipping it upside down, to get all the oil out, you will need to pump the damper rod in and out of the fork a few times, get out as much as you can.

If you want to just change your fork oil (normal service) then you can go to the bottom of this.

Lay the fork on its side, with a small flat head screw driver, wedge it between the outer fork tube and the dust seal, working around the seal, separating it from the outer fork tube
http://gsxr-freak.gixxer.com/MVC-009.JPG

Take the flat head and remove the oil seal retainer (it is a small metal ring between the dust seal and the oil seal)
http://gsxr-freak.gixxer.com/MVC-010.JPG
http://gsxr-freak.gixxer.com/MVC-011.JPG

Separate the two fork tubes, holding one in each hand, slide the inner tube out till it stops, then with a few good movements, you need to slide them in a bit and pull them out hard. With a few tries it should separate Vid (http://gsxr-freak.gixxer.com/MVC-012.MPG)

Take the outer tube and set it a side

Stand up the inner tube, with the flat head screwdriver you need to separate and then remove the top fork bushing, then the bottom bushing, then the thick washer (note what side is up), remove the oil seal (take note as to top side), retainer clip, and dust seal
http://gsxr-freak.gixxer.com/MVC-013.JPG
http://gsxr-freak.gixxer.com/MVC-014.JPG

Check the inner fork tube for any nicks or scratches, if there are use a very fine sandpaper (1000 grit) to try and smooth out the rough edge

Clean the inner fork tube off, if the tube feels dry, use something like WD-40 to lube it a bit

Use a plastic bag to cover the top of the inner fork tube, to make it a bit easier, put a small amount of oil on the bag, slide the dust seal over the bag and down the tube, then retainer clip and the oil seal
http://gsxr-freak.gixxer.com/MVC-015.JPG
, remove the bag, then the large washer, then the two bushings just as they came off.

Slide the outer tube back over the inner,
http://gsxr-freak.gixxer.com/MVC-016.JPG
to seat the oil seal I used a piece of PVC pipe that is close to the size of the inner tube, then cut it in half, using a hammer I tapped the PVC pipe on the oil seal, working around the seal, driving it into place. You know it is all the way on when you can see the grove that the retainer clip

Install the retainer clip

To help keep the seals from drying out, and dirt getting to the oil seal, I put some grease between the oil and the dust seal
http://gsxr-freak.gixxer.com/MVC-017.JPG
, then push the dust seal back into place

Slide the fork in and out a few times and wipe up any grease that may come out.

Turn the fork right side up, and start to fill the fork with oil (5w is stock), pump the damper rod till you feel all the air out (smooth action)
http://gsxr-freak.gixxer.com/MVC-019.JPG
If you have a fork level set then fill it and set it to 99mm
http://gsxr-freak.gixxer.com/MVC-020.JPG
, if not fill the fork with 480ml (per the shop manual)
http://gsxr-freak.gixxer.com/MVC-018.JPG
As a side note, don't be like Cliff here and lay the fork down without the cap on it… LOL
http://gsxr-freak.gixxer.com/MVC-021.JPG

Reinstall the spring and spacers, then the fork cap the same way you took it off. Then the preload adjuster, and the retainer.

Your done… I have a few pics of the dual rate crossovers made by Works Performance, they work very nice and replace the spring spacer, making street ridding nice and soft, with canyon ridding still being stiff. If you would like any more info on them please let me know.
http://gsxr-freak.gixxer.com/MVC-023.JPG
http://gsxr-freak.gixxer.com/MVC-024.JPG
http://gsxr-freak.gixxer.com/MVC-022.JPG

If you have any questions please feel free to drop me a line…

John

[ 01-24-2002: Message edited by: Hunter ]</p>

<blockquote><font size="1" face="Verdana, Arial">quote:</font><hr>Originally posted by migz123:
Great Stuff John - saved, printed out and kept -<hr></blockquote>

Keep in mind that your bike is different... It should be about the same but there may be a few things that dont match up... You have the standard forks, the 750 has a inverted fork... I have not yet taken your style apart...

John

hey John, how about you just make a directory on your site "forks" and then number the images 1-2-3 etc.... then just reference which image goes to which step and put the link for all the images at the beginning.

I can host if you need more space, but I cant change the code to allow more than 8 images per post images/icons/wink.gif

you could always split it up into a few posts if you want,

Well if people just copy the address to a new window, they will get the pics... I just wanted to get them all in there... It is probably a good thing that they dont show, they are very large in viewing size... It would make the post VERY VERY long with them all showing... images/icons/smile.gif

John

i edited your post so people can just click on the links instead of having to copy them and paste them into a new browser window. hope i didn't butcher it. images/icons/wink.gif

I tried this as well.. But as it is now.. like before... I get an access forbiden when I click. Does everyone else get this too??? It works if I copy and paste it in a new window...

John

Hey John..thankx for posting that... images/icons/grin.gif images/icons/grin.gif

<blockquote><font size="1" face="Verdana, Arial">quote:</font><hr>Originally posted by GSXR-Freak:
I tried this as well.. But as it is now.. like before... I get an access forbiden when I click. Does everyone else get this too??? It works if I copy and paste it in a new window...

John<hr></blockquote>

when i clicked on one of the images it came up fine.. except for the scary person in the background holding the fork.. images/icons/grin.gif is that you with the little fur on your chin, the silver earings, and the S&S Steel jacket?

<blockquote><font size="1" face="Verdana, Arial">quote:</font><hr>Originally posted by Hunter:


when i clicked on one of the images it came up fine.. except for the scary person in the background holding the fork.. images/icons/grin.gif is that you with the little fur on your chin, the silver earings, and the S&S Steel jacket?<hr></blockquote>

OMG NO!!! LMAO... I knew I should have said something about that... That is Cliff, it was his bike that we did the forks on. It was late and he wanted to go home... But I was taking my time with taking the pic for this.. LOL... Doesnt he look like he is on his way down from a long crack trip?? LOL

John

whew!! you had me scared for a second. images/icons/grin.gif

No I would have gone to the plastic sergen before getting the bike.. images/icons/wink.gif

John

I'm going to save and print that out, thanks bro.

For your 96 it should be about the same... You might have a size change on a few of the bolts, but nothing major.. The shop book for the bike is listed from 96 - 99. so it comes apart the same way... images/icons/smile.gif

John

iight

Pics don't work!?

Pics don't work!?

lol this thread's a bit outdated