Installed RPM valves, Racetech springs & Rebuilt forks

[FJmonkey]

One step closer to 17" x 3.5 front with Blue dots and RPM cartridges. Quite east but very messy. Could have saved some time with a parts cleaning bath.  Drained the forks the day before and let them sit over night so the last bit of oil settles to the bottom. The odor of the oil was an olfactory assault, black and stinky. Ed's old forks were over due for an overhaul.... I used an impact gun to remove the bottom bolts first, very easy this way. Also very easy to re-tighten them. Capture the copper washers for a thermal cycle with some MAP gas to soften them back up. Made a tool to turn the caps off. A 3/4-10 x 3" bolt with some time on a belt sander so it fits the 28mm tapered hex. The cap socket is tapered, at the top it measures just over 28mm, measure deeper in and it drops 1mm. I was pushing down and almost cramping to keep the cap from bouncing off my forehead. With the pre-load set at the minimum setting it does not take much to hold it down once the threads are clear the cap pops up. Slowly took one fork apart to see how the bits come out. I took a few pictures knowing it may help some you knuckleheads thinking of rebuilding your forks yourself.

First, the old oil, pic is out of focus but it is quite clear the oil has returned to black crude.


The next two has the old bits all out and some of the new bits.



FYI Simi_Ed, the flower pots were upside down. Not sure what that does to the forks performance but I went slow and careful and saw for myself.

Cut the dampener adjusting rod about 2" from the adjusting head and throw the cut rod away!!!


Now my next task is finding a 14mm brake master, and watching for the UPS truck to deliver the new rotors. Then bolt up the "new to me" front end and get some shake down runs in before WCR.

[Lotsokids]

Has you wife been looking for her towels yet?

[FJmonkey]

Has you wife been looking for her towels yet?

Towels??? I have an abundance supply, its my wife that changes towels more often that she changes her mind...And that is scary fast. She can change her mind and take them back anytime. 

[big r]

Hey, Monkey I just got the whatfor from the other half for rebuilding my clutch master on the kitchen table this morning. Used what I thought was an old towel, Hah my mistake I'm in the doghouse for the rest of the day.

[FJmonkey]

Hey, Monkey I just got the whatfor from the other half for rebuilding my clutch master on the kitchen table this morning. Used what I thought was an old towel, Hah my mistake I'm in the doghouse for the rest of the day.

Sorry to hear that, I have pile of old tossed out (she throws them in the garage for me to find later) towels you may have, you pay the shipping....

[The General]

Hey, Monkey I just got the whatfor from the other half for rebuilding my clutch master on the kitchen table this morning. Used what I thought was an old towel, Hah my mistake I'm in the doghouse for the rest of the day.

Sorry to hear that, I have pile of old tossed out (she throws them in the garage for me to find later) towels you may have, you pay the shipping....

Mine get old prawn heads added. 

[Mark Olson]

hey Monkey ,  good of you to take pictures of the proper placement of the parts 

everybody who has done this mod in the past forgets all the little details.

personally my haynes manual has my personal notes added as well as dates and years of parts fitted.

keep up the good work and I will see you at the WCR so I can make fun of you in person for your power ranger outfit.

[soundmindryan]

I thought this ecent post would be a good place to reveal my latest discovery concerning supposedly "rebuilt" forks. If you recieve a set of rebuilt damper rod forks from an unknown (or known for that matter) source, it's a good idea to at least pull the fork cap put and check the engagement of the adjustment "D" rod. On a set of '87 forks that were "totally rebuilt," BOTH of the damper adjustment rods were inserted into the wrong hole, meaning the only adjustment you'd have is the increased amount of metal shavings that would build up in your forks each time they cycled up and down. Fortunately, I purchased the forks for the upper tubes only and will be using my '89 internals. (well... when I find another '89 lower left slider to replace my bent one.) Moral: Trust only the trustworthy and be careful where you insert your damping adjustment rod.

[racerrad8]

I thought this ecent post would be a good place to reveal my latest discovery concerning supposedly "rebuilt" forks. If you recieve a set of rebuilt damper rod forks from an unknown (or known for that matter) source, it's a good idea to at least pull the fork cap put and check the engagement of the adjustment "D" rod. On a set of '87 forks that were "totally rebuilt," BOTH of the damper adjustment rods were inserted into the wrong hole, meaning the only adjustment you'd have is the increased amount of metal shavings that would build up in your forks each time they cycled up and down. Fortunately, I purchased the forks for the upper tubes only and will be using my '89 internals. (well... when I find another '89 lower left slider to replace my bent one.) Moral: Trust only the trustworthy and be careful where you insert your damping adjustment rod.

Or better yet...

Cut off the damper "D" adjusting rod so that cannot happen again and install a set of RPM fork valves.

Randy - RPM

[soundmindryan]

That is first on my list. 

[baldy3853]

Sorry to hear that, I have pile of old tossed out (she throws them in the garage for me to find later) towels you may have, you pay the shipping....
[/quote]


Bugga Monkey what do I get now when I visit now you've used my towels 
Baldy

[FJmonkey]

Here is an update:
After discovering my upper fairing is way too knackered for me to fix before the WCR I call in to San Dimas Mike to get my alternate fairing from him. New to me faring saves me lots of critical time for this build. I start repairing some other tabs that have been broken or were newly discovered knackered. I got all the bits put back on today except for the front fender, still rebuilding one missing tab. Here is what I have done for this upgrade.

89' forks, thanks Simi_Ed
Blue dot clipers, thanks Simi_Ed
SST brake lines, thanks Simi_Ed for getting them made when you did yours.
RPM fork cartridges, thanks Randy
0.85 straight rate springs, thanks Randy
HH pads for blue dots, thanks Randy
New fork seals and bushings, thanks Randy
87/88 FZR1000 17 x 3.5 front wheel
New wheel bearings and seals, thanks Randy
New Dunlop Q2 17 x 120 x 70 (to match the rear)
New knockoff Galfer rotors that LA_Mike has been using.
New Kawasaki Concour brake master (5/8" not 14 MM)
New brake lever as the master was without.
I think that covers it but I might add some forgotten items.

Took it for the first shake down run today....Holly Crap!!! Making that many changes at the same time is like drinking Kookaloo from a fire hose. The front tire is new so I am going gentle as I scrub it in. I cannot believe the transformation all the changes have made. I wish I could have done them one at a time to see the effect each had on feel and performance. The new front tire feel was there, very easy neutral steering, almost pulling me lower and over steering. The RPM cartridges had a distinct and noticeable effect. The dive effect was better controlled at any speed. I took some of the rougher roads on the back side of the Crest and found myself feeling very comfortable in corners that before made me feel like slowing down from the washboard effect. I hit the reflectors on purpose and was surprised that the tiny bumps are almost noticeable. Braking in a corner had less dive and less stand-up effect. This makes braking in a corner safer if I come in too hot and need less speed. On the other hand, with the corners feeling so much better I will just likely tuck in more and hang on like an FJMonkey on Kookaloo. It was only 37 miles but Damn!!! It was like a new bike that loves the corners more than I do. The brakes feel much better even with a 5/8 master. Almost glad I did not jump to the 14MM, might have been doing stoppies and crapping my Red Power Ranger suit.

WCR here I come!!

[Mark Olson]

way to go Monkey Man.

just wait till the tires are scrubbed 

[fj11.5]

nice work mate, but go for the 14mm master , much less effort to use, works better and has less of the nose dive effect as it gives more control

[FJmonkey]

nice work mate, but go for the 14mm master , much less effort to use, works better and has less of the nose dive effect as it gives more control

Its on the list, after the rear shock...