ForkMods?

[marti]

Hi, i need to replace the fork seals on my standard forked 3tj,
i will be fitting an fzr600r motor soon.
Does anyone know how much oil to put in each leg?
Is it worth adding spacers/thicker oil?
I weigh 11st and thers an r6 shock on the rear
Cheers

[Hogdigerdy Dog]

standard tj non adjustable forks are 509ml oil (10wt) or 80mm from the top of the slider with forks compressed and no springs
a good upgrade would be maxton springs and spacers to suit your weight at about £120 the pair,
although the forks are non-adjustable you can adjust the pre-load by shortening the spacer (or lengthen them which is a bit hard if you've cut them down )
maxton sent me spacers about 10mm to long so i had some play, just ask em there pretty good, i actually ended up about 4mm shorter than they recommended but maxton deal predominantly with race bikes so are a bit on the hard side for road use

[cagiva996]

ditto the maxton springs i used some 9kg ones and cut down some early r6 spacers til i got the right amount of sag.the r6 forks and the 3tj sp forks are very similar(and both 43mm) if i remember rightly and i did wonder if you could put the 3tj stanchions in the r6 fork legs so you could then use the r6/r1 calipers to get the right fork lenghth as the r6 ones are a fair bit longer than the tj ones,mmm now wheres my tape measure

[Evilchicken0]

I was pondering that very question just the other day. Let me know what you come up with.
I reckon it would probably work with the SP stanchions because they're both cartridge forks but the standard RR's would be more suited to FZR1000 bottoms.

[marti]

Thanks for that guys, some very good ideas there!
I did think of putting r6 forks on as ive got early r1 calipers and wheels lying around.
Anyway ive stripped the forks, but the bottom bolt is turning!
I did notice a star shaped cutout inside the forkleg, perhaps i could get a large allen key in there
anyone know what size?
Or would it be easier to wind a couple of screws into the seal and wind it out?

[Evilchicken0]

Use a wooden broom handle, knock it down with a hammer and it should give you enough purchase to turn the nut / bolt from the other side

[Hogdigerdy Dog]

just for a different angle on this, i use a length of 1/2" bar with the right sized nut welded to the top, 29mm across the flats if i remember correctly



loads of peeps use the broom handle method with good affect
but i cant see how hammering a piece of wood into an ally damper is gonna do it any good at all
horses for courses though, do what works for you

[marti]

Thanks again, i tried the broomstick method with an air impact but no go.
Perhaps i should have hammered the broomstick in harder, but didnt fancy it.
Ive seen some 3/4 unc nuts n bolts lyin around in work they were 28mm a/f.
Might weld one on some stud bar and try that

[Hogdigerdy Dog]

i used 1/2" square bar only because it makes it easier to get a spanner on the bar to hold it still, then turn the alen bolt at the bottom,
with a round bar you'll need mole grips, which just make the job harder and you may need 3 hands
if the nut's a tad small you could always put a bead of weld round it then grind the bugger to size,
as you can see from the pic, i used 2 before i got it right (and 1 on the other end of the bar so that's 3 ) but once you've got it made, that's it, no more beating up the damper rod with a broom and hammer

[Evilchicken0]

Is this a nut or a bolt ???