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Discussion Starter #1
Been two year since I put the SONIC springs in & serviced the forks,
As I'm getting the bike ready for the riding season & the upcoming Dragon run,
I figured the forks were due another service.

Iv been in the shop forking around all day,
Ok were going to remove the forks on my 07 ZZr/2002 J model.
First we gotta remove the wheel, We start with the finder....


Put it aside, along with the R&G fork sliders....


Just a quick look @ one of my favorite tools...


Ok time to remove the calipers, Then loosen the rotor bolts, (no need to remove em now)
Now put the bike on the stand & remove the wheel.

Now is a good time to check your forks for run-out,...

Put a finger in the bottom of the fork & twist the lower fork,
While you turn the fork, watch the fork, Is it walking(moving off center?
You should be able to see this & feel it with your finger.
If the fork moves from center, Your fork may be tweaked/bent.


Now to loosen the top cap, but first loosen the top yoke bolt.

now the cap, Be careful here, Its easy to slip & ding something, I like to cover the tank when working around it.


Now there's still two more bolts on the lower triple, get those & your fork is ready to come out

Now your fork is out, you want to remove the cap, Its the 27mm socket you saw a couple pics up, Its already loose just turn it till it pops up.
Your still not done, Take two 17mm wrench's, Put
one on the nut you see here, You don't want to turn this one, Just hold it in place while you turn the top of the valve(blue) with the other 17mm wrench

Now count the threads from the nut to the top of the rod, Write this down for future reference...

Forks are independent mechanical unit's that work together as one function. However they must be set exactly the same to perform correctly.
Every adjustment you do to one you must mirror with the other.
This is especially true when reassembling,
6 threads on this rod means 6 threads on the other, (so write this stuff down.

The valve, nut, washer, spacer, & washer, Just as they come out, reverse for reassembly.
(Mark, do you recognize the blue towels??)


Tomorrow I'll show you what I got out of the forks. not pretty.
 

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Discussion Starter #2
Ok before we pour out the old fluid we need to measure the amount, so we know about how much to put back in.
Lots of things can be used for this , The zip-tie was handy, place a peace of tape at one end,
Stick the zip-tie into the fork aligning the tape with the top of the fork(tube extended, spring out)
Remember to do it the same way when you refill.


Remove & there will be fluid/oil on it just like a dipstick,
mark the spot with a marker...


Now pour out the old oil...

yeah nasty stuff, But wait it gets worse, The nastiest stuff is in the bottom & trapped in the lower cartridge.
were going to get to that,
But this is what the fluid looked like when it went in (2010) & now...


Now to remove the lower cartridge, A special tool is required to do this, (well so sayeth the shop manual)
Of course here in Redneck land, we improvise)
First locate this 10mm bolt @ the bottom of the fork.


Hears my homemade tool, yeah its a piece of PVC pipe,


cut to fit....


Like so..


Inside the fork tube it looks like so..

Whats happening here is were turning the 10mm bolt @ the bottom & holding the cartridge with the tool, see the cartridge will spin with the bolt & never come out,
Problem is its to far down into the fork to get to with any conventional tool,
so we improvise.

cartridge out...

(I need to make a better tool)
A note here, Be careful what you make your tool of, Don't want to scratch the inside of your forks.
Plus be sure whatever you use is clean, We don't want to introduce contamination into the forks( If you use PVC, be sure there are no shavings on your tool)
 

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Discussion Starter #3
I put em back together today, & my tool worked like a charm.
Maybe i don't need another after all.
 

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Discussion Starter #4 (Edited)
Almost forgot,


This bolt is a replacement, When I went to loosen the triple bolts, I found no bolt here.
Yeah it was gone,
Iv only got myself to blame, Must not have torque it down properly.
I do know when it happened though, A few months ago I took the caps off to have a look at the valves, ???
 

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Discussion Starter #5
Had to make a run to the parts store for a couple crush washers, Iv got a drawer full, But none the right size.



And this damn bolt was holding me up.
That's tape, but blue spokes might look nice.????
 

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Discussion Starter #6
Two fresh forks, ready for paint.



Painted


Stripped & polishing, Paint will come tomorrow.
 
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