fork seal replacement to send

8/2/2019 Fork Seal Replacement to SEND

1/19

Fork Seal Replacement!Fi rs t o f f , the fo rk seen in t he p ics i f f rom a 2005 GSXR1k, t he d i f fe rence a re min . bu t as fo l l ows:- Busa has a larger 30mm hex ontop of the fork nut

- Busa has an Aluminum Spacer rather then the white plastic one seen on the 1k. As part of the 1k, thereis a cup on the end of the fork nut to keep the spacer from getting chewed up. The Busa has a cup b/w

the spring and spacer, not the spacer and fork nut.

Beg in ing . .. . How to Make a Fork Serv i ce "Too l K i t "

I used a 2" I.D. galvanized pipe from Home Depot Plumbing Department. 2each 1/2" -13 24" longthreaded rod, with 2 matching nuts. Drill a 1/2" hole in both sides of the pipe, as straight across as

possible. Tap the holes with a 1/2" -13 tap. Grind down one end of each threaded rod, making it approx.5/16" dia. Thread a nut onto each grounded end about 2", and thread the rod into the pipe. This is now

your spring compressor.Next, using a galvanized piece of steel, I drilled 7/16" hole, about the middle of the plate, and then cut it

using a dremel, so there is a channel. This is the spacer-jam.

No w fo r t h e f u n p a r t . Re mo ve o n e f o r k , g ra b a f r i e n d a n d en j o y !

* * NOTE* * I F YOU ARE ONLY CHANGI NG SPRI NGS, FLUI D AND OR SEALS, DO NOT TAKE THECARTRI DGE OUT. JUST PUMP THE FLUI D OUT AND SKI P TO THE SEAL, OR FLUI D PART.


2/19

L oo sen t h e f o r k n u t , p re fe ra b le w h i l e st i l l b o l t e d t o t h e t r i p l e c la mp . Th en u n sc re w i t f r o m th e

u p p e r f o r k t u b e a s sh o wn h e re .


3/19

Sl i d e t h e u p p e r f o r k t u b e d o wn t o t h e b o t t o m p o s it i o n .

Sl i p yo u r f o r k sp r i n g co mp r e sso r yo u j u s t m a d e ove r t h e f o r k n u t , t h r e a d t h e ro d s so t h e

g ro u n d d o w n e n d i s i n s id e t h e h o l e o f t h e sp a ce r ( w h i t e p l a st i c t u b e , b u t o n t h e Bu sa i t sa l u m i n u m ) .


4/19

Have you assis tan t ho ld t he fo rk tub e s teady, w h i le you compr ess the sp r ing . Once compr essed

your ass istan t needs to sl i de th e spacer - j am over th e spacer and be low t he jam- nu t . Th is w i l lcap tu re th e sp r ing in a com pressed sta t e , a l l ow ing access to ho ld t he jam -nu t so you can

u n s cr e w t h e f o r k n u t .

L oo k i n g d o w n f r o m th e t o p , t h e p i n s en g a g e d i n to t h e sp a ce r .

Co mp r e ss i n g t h e sp r i n g , n o t so ea sy f o r a l i l 1 6 5 l b s tu d l i ke m e b u t i t can b e d o n e (FW I W t h e

stock 1K sp r ings a re a l so .95kg sp r ings) .


5/19

Sl id ing the spacer - j am in t o pos i t i on , aga in , be low t he jam nut and above th e spacer .

Close-up o f th e spacer - j am


6/19

1 7 m m w re n ch on t h e j a m -n u t , a n d so cket o n t h e f o r k n u t , lo o se n i t u p ma n !

Re mo ve t h e f o r k n u t .

Rem ove the Rebound Ad jus t m ent Rod , s imp ly pu l l up , w a tch ou t t he re i s o i l i ns ide i t .


7/19

Com press the sp r ing aga in so you can rem ove the spacer - j am . I t w on t necessar i l y go shoo t ing

u p o u t , b u t i t w i l l p o p b ack u p a l i t t l e so ke e p con t ro l o f t h e co mp re ssor t o o l .

Sp r i n g co mp r e ssed a n d sp a ce r - j a m re mo ve d , care fu l l y l i f t t h e co mp re ssor u p a n d re m o ve t h espacer .


8/19

Ne x t p u l l t h e sp r i n g o u t . * NOTE* o n t h e Bu sa t h e re w i l l b e a sma l l me ta l cu p o n to p o f t h e

spr ing , mak e su re you check how i t i s p laced on th e sp r ing .

I n ve r t f o r ks t o d ra i n oi l .

Up si d e r i g h t , w e s li d e t h e u p p e r t u b e o f f t h e l o we r t u b e .


9/19

I n ve r t l o w e r t u b e , g rab t h e car t r i d g e an d p u m p a f ew t i m e s t o f i n i sh d ra in i n g a s m u ch o l d f or ko i l as possib le .

I n ve r t l o w e r f o r k , h o l d in g car t r i d g e ro d t o t h e s id e , a n d re mo ve t h e 1 0 m m h e x h e a d b ol t .There i s a copper w ashed on the bo l t .


10/19

Pu l l t h e ca r t r i d g e o u t a n d p u m p to re mo ve a l l o i l .

The bo l t and copper w asher . Clean the bo l t and rep lace the copper w asher .

Care fu l l y pu l l the dust cover o r w iper ou t , care fu l no t t o scra tch th e inner fo rk t ube .


11/19

Wi p e r o u t !

Rem ove the Sea l re ta ine r sp r ing . Sim p ly pu l l one s ide ou t , and ro ta te a round , i t i s a sp l i t r i ng

f i t t e d i n to a g r o o ve .

Sea l re ta ine r r i ng ou t !


12/19

Care fu l l y p r y t he sea l ou t , aga in , don t scra tch t he inner t ube a rea .

Sea l sea t , under the sea l , j u s t w ipe i t c lean so you can inspect the inner r ace/ bush ing .

I u se d a Q- t i p t o c l ea n t h e g a ske t a re a t h a t t h e cop p e r w a sh e r w i l l se at , f o r t h e car t r i d g e b o lt .


13/19

I n se r t car t r i d g e , a n d p re ss t h e t o p o ve r t o o n e s i d e. L ock t i t e t h e b o l t , i n se r t i n b o t t o m o f l o w e r

tub e , and t i gh t en to spec.

Ti g h te n e d d o wn !

Ho l d t h e ro d u p f o r e as i er f i l l i n g . Sta r t o u t w i t h a b o u t a 1 / 4 q t . Th e n p u mp th e ca r t r d i g e , i t w i ld rop leve l qu ick l y as th e ai r i s remov ed f rom ins ide the ca r t r i dge .


14/19

Just a bonu s sho t .

I ns ta l l Sea l seat .


15/19

I ns ta l l seal , PN face you as your p ress ing them in .

I n s ta l l sea l r e ta in i n g r i n g , p ress i t i n t o t h e g ro o ve a n d wo r k i t a ro u n d . I f i t s n o t i n t h e g ro o vethe sea l i s no t fu l l y sea ted .

I n s ta l l Du st w i p e r , si mp l y p re ss in to f u l l y se ate d p o s i t i o n .


16/19

I ns ta l l ed v iew , lube the w iper and sea l i ns ide su r face to p reven t sea l dam age dur ing assem by.

Ca re fu l ly s l i d e u p p er t u b e o ve r l o w e r t u b e , a n d w o rk i t s w a y d o w n to t h e f u l l y se a ted p o s i t i o n .I f t h e re i s an y r e si s t a n ce yo u m a y h a ve a b e n t f o r k ( t h i s w a s t h e case o n t h i s p a r t i cu l a r f o r k

se t ) .

Go ahead and f i l l w i th fo r k o i l . Once fu l l , pump t he car t r i dge rod abou t 10 t im es, and then le ts i t a f e w m i n u te s t o e n su re al l a ir i s o u t o f t h e syste m . A f t e r t h a t y o u t r i p l e ch eck f l u i d l eve l ,

a n d m a ke su re i t s f u l l .


17/19

I u se d t h e Re b o u n d ad j u s tm e n t r o d t o m a rk t h e 3 .9 " t h a t t h e Bu sa re q u i res t h e f o r k f l u i d t o b e

a t . Me asu re me n t i s t a ke n f r o m th e t o p , w i t h t h e u p p e r t u b e f u l l y b o t t o m e d o u t o n l o we r t u b e .

D ra w a ma rk a t a p p ro p r i a te l eve l .

Ho l d ro d i n si d e t u b e , a n d t h e b o t t o m o f t h e ro d sh o u l d b a re ly t o u ch t h e e n d o f t h e ro d w h e n

th e m a rk i s l eve l w i t h t h e t o p o f t h e t u b e s.


18/19

I n s ta l l n e w sp r i n g , o r o l d o n e i f yo u l i ke . L ow e r i t i n so yo u d on t sp l a sh o i l eve ryw h e re .

Grab t he spacer and compr essor , p lace over the fo r k sp r ings, and compr ess once aga in , and

s l ip the spacer - j am in t o posi t i on . Be fo re you compr ess, l i f t the rod to the fu l l es t ex t ended

p o s it i o n , it w i l l s i n k sl o w l y a s yo u r com p re ssi n g , so wo rk q u i ck . I f i t s t o o lo w to g e t t h e j a mp l a te in , t h re a d f o r k n u t o n to ro d a n d l i f t t h e ro d w h i l e co mp r e ss i n g sp r i n g .

Befo re f i n a l in s ta l l of f o r k n u t , m e a su re t o e n su re t h e re i s 1 1 mm o f t h re a d sh o w i n g f r o m e n d o f

t h e ro d t o t o p of n u t . I f n o t yo u r a d j u s tme n t r a n g e w i l l b e h in d e re d . A l so , l o ck t i t e o n t h e f o r k

n u t . Ti g h e n f o r k n u t w h i l e h o l d i n g j a m -n u t .


19/19

Com press sp r ing aga in to rem ove the p la te . Let th e spacer assem b ly r i de up and engage the

f o r k n u t .

L if t t h e u p p e r f o r k t u b e u p , an d t i g h te n t h e f o r k n u t t o t h e u p p e r t u b e . Co n g ra t s yo u r d o n e !

No t r e a l ly , yo u h a ve o n e mo re f o r k t o d o . Bu t d o n t yo u a l r e ad y f e e l b e t t e r a b o u t t h i s !

fork seal replacement to send

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