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Old 10-22-2012, 04:28 PM   #1
BeerGarage
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1986 750 forks: home made special tools?

Hi

I plan to change the fork oil and seals on my 1986 750.

Do I need the special tool to remove the fork outer bushing? Any home made tool ideas for that? I would like to know I can get the bushings out before I buy them. I finally found the bushings online and they are not cheap, Race Tech Super Slick Fork Bushings, FMBI41201P and FMBO41122P.

Also, I found on this forum (shoot, I can't find the thread now) that the special tool for the 1986 1100 damper rod is a 25mm hex and the seal driver is sched 60 PVC. Are these correct for the 750?

Thank you very much for any help.

Cheers
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Old 10-23-2012, 03:14 AM   #2
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Re: 1986 750 forks: home made special tools?

use air rattle gun to undo damper rod cap screw at bottom of leg, no need for 25mm hex.
If I remember right the outer bush will came out with stanchion.
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Old 10-23-2012, 08:55 AM   #3
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Re: 1986 750 forks: home made special tools?

Thank you for the reply. I still do not understand.

If I use the air rattle gun / impact wrench, what attachment do I use to attach the gun to the damper rod (How do I get the gun to grab the damper rod)? I thought THAT was the 25mm hex ATTACHMENT between the gun and the rod.

Thank you
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Old 10-24-2012, 12:56 AM   #4
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Re: 1986 750 forks: home made special tools?

Quote:
Originally Posted by BeerGarage View Post
Thank you for the reply. I still do not understand.

If I use the air rattle gun / impact wrench, what attachment do I use to attach the gun to the damper rod (How do I get the gun to grab the damper rod)? I thought THAT was the 25mm hex ATTACHMENT between the gun and the rod.

Thank you
No, you undo the cap screw at the bottom of the leg (down were the axle slides through)
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Old 10-24-2012, 10:27 AM   #5
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Re: 1986 750 forks: home made special tools?

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Originally Posted by Karitane Pete View Post
No, you undo the cap screw at the bottom of the leg (down were the axle slides through)
OK. I start wrenching and rattle it out. Thank you.
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Old 11-11-2012, 06:56 PM   #6
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Re: 1986 750 forks: home made special tools?

Thanks

I used an impact wrench to get it out:


And made a special tool out of a carriage bolt to tighten it:




And I did a full writeup:
http://http://beergarage.com/GSXRForkSeals1.aspx

Cheers
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Old 11-13-2012, 05:46 AM   #7
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Re: 1986 750 forks: home made special tools?

Thanks for taking your time with the writeup and pics.
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Old 11-13-2012, 06:02 AM   #8
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Re: 1986 750 forks: home made special tools?

Indeed, well done
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Old 03-05-2014, 04:10 PM   #9
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Re: 1986 750 forks: home made special tools?

Hi guys,

I,m slowly restoring my bike,and i,m nearing completion.

I,ve removed forks,and when i try to undo the allen head bolt at bottom of forks,the inside part its attached to, turns.

i tried to open link in beer garages post but won,t open for me,does this modified carriage bolt go inside the fork tube?

Does anyone know how much oil goes back in?

Appreciate any help

regards craig.

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Old 03-05-2014, 11:40 PM   #10
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Re: 1986 750 forks: home made special tools?

417cc SAE 15 according to the Clymer manual. Or oil level of 159mm (completely compressed without spring).

Yes it is for down the fork leg. It can be a real prick of a job as the bolt is torqued to 55-70nm and as you've discovered the damper rod will rotate. Go make the tool above, or rattle gun - you'll also find homebrew solutions involving wooden dowels/broom handles as friction devices. I needed rattle gun for one leg both to undo and do up again.

Whatever option you take make sure you clean them out, doesn't take much to block an orifice.

If you're only doing the oil & seals you can do it without dismantling the lowers, by overfilling the forks with oil removing the dust seals + circlip and compressing them until the seals pop up the stanchions.

Or don't fill, take dust + circlip carefully pierce them and pick them out, hollow pvc pipe of correct diameter will drive the new seals home. Lots of ways to skin a cat, some more sketchy than others.
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Old 03-06-2014, 02:03 AM   #11
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Re: 1986 750 forks: home made special tools?

Hi mate,

I was wondering if i could cheat,thanks for your advice,because i,m going MAD looking for a bolt head the right size,frocking around for way to long,need it done.

thanks again.

craig
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Old 03-06-2014, 06:15 AM   #12
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Re: 1986 750 forks: home made special tools?

I've pushed against them with a broomstick handle before, sometimes it doesn't take much. An impact gun will usually take them right off, even the electric or battery powered ones if you can get one.
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Old 03-06-2014, 09:43 AM   #13
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Re: 1986 750 forks: home made special tools?

Here's a neat video I came across. I'll be respringing my forks this weekend. Hopefully it's as easy as this guy makes it look. Listen starting at the 0:38 part


Last edited by ieatglue; 03-06-2014 at 09:51 AM.
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Old 03-06-2014, 02:13 PM   #14
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Re: 1986 750 forks: home made special tools?

Hi,
I watched this on youtube and its nothing like what he is doing,the allen head bolt is much harder than that,and he turns it one revolution once cracked.After mine cracked the inner part turned and i could not free it up.

Last night i removed dust seal and clip and a spacer,but unfortunately the seal could not be picked out as it seams to be partly made of steel.

I,m going to take to town today and find correct size large bolt to fit down inner section,and ill let you know what i come up with.

The over filling of oil might work,broom stick sound good also,but i need O rings to reseal the anti dive parts,to i need to go to town.So ill make the correct tool then.

found this image,i think by looking down fork tube looks like this.

http://www.motorcycle.com/images/con...t/rodntool.jpg

Last edited by monaro; 03-06-2014 at 02:15 PM.
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Old 03-06-2014, 06:42 PM   #15
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Re: 1986 750 forks: home made special tools?

Hi time for an update,

Hope this helps others at home.

Went to hardware,no cap head bolts big enough,call into irrigation shop,before heading off to big smoke,and doctored this up in store.Then tack welded and linished to fit ,once ready,took one minute to undo by myself,2 people would be easier though.

When undoing the top piece,use a rag over the top as spring is under pressure and pops open,and spring is sharp on knuckles,ouch.

On receipt old mate forgot to charge me for the big nut,lol.

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Old 03-06-2014, 06:45 PM   #16
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Re: 1986 750 forks: home made special tools?

Glad i opened up,as its filthy inside.
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Old 03-06-2014, 06:57 PM   #17
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Re: 1986 750 forks: home made special tools?

Amazing write up! My weekend just got a whole lot easier
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Old 03-06-2014, 07:02 PM   #18
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Re: 1986 750 forks: home made special tools?

cheers,glad to help.

I tried broom handle first,that was a nightmare,as broom is to small, so this was my backyard solution.

have fun
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Old 03-06-2014, 08:57 PM   #19
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Re: 1986 750 forks: home made special tools?

Here is BeerGarage's gsxr site, left side of the page has the navigation links.
http://BeerGarage.com/GSXR.aspx
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Old 03-07-2014, 01:14 AM   #20
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Re: 1986 750 forks: home made special tools?

Beer O clock,

finished for today,i,ll load some more pics,they should help,i found a better way to use my tools on reassembly as you have to hold upright to finish off.
When thread is wound out about this much place a rag over top to finish pulling apart.

Parts in order.
Close enough colour match,seeings it would be faded about now,lol.
measured 159mm from this point,which is shoulder of syringe,to end of clear tube,filled ,pumped shock tube up and down about 20 times to bleed all air,sucked out excess.
That will do for my rostered day off.

Last edited by monaro; 03-07-2014 at 01:20 AM.
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