1989 Front Fork Disassembly

[rmadursk]

I am starting a new project. 1989 FZR1000. Pretty much completely disassembled to paint/powdercoat/polish. However, I cant seem to get the inner fork tube apart. There is a bushing in there but I don't see a way to press it out. Any pointers would be appreciated.

Thanks,

Ron Madurski

[reelrazor]

Take the bolts out of the bottom of the outer fork tubes (allen headed bolt in axle recess-can see it thru hole in bottom of outer leg).

This can be done easily with an impact wrench. If no air tools available, then you will need to get/use an inner damper rod holding tool (the damper rod being the piece that the bolt threads into-and consequently the piece that keeps the two fork legs together).

Once that bolt is out you can use in inner leg as a slide hammer to pull the upper fork bushing out (in fact they won't come apart without that happening).

Here's the factory manual: Fork disassembly starts on page 31

http://www.fzrarchives.com/fzr600/600_m ... pt%201.pdf

[sweekster]

Take the bolts out of the bottom of the outer fork tubes (allen headed bolt in axle recess-can see it thru hole in bottom of outer leg).

This can be done easily with an impact wrench. If no air tools available, then you will need to get/use an inner damper rod holding tool (the damper rod being the piece that the bolt threads into-and consequently the piece that keeps the two fork legs together).

Once that bolt is out you can use in inner leg as a slide hammer to pull the upper fork bushing out (in fact they won't come apart without that happening).

Here's the factory manual: Fork disassembly starts on page 31

http://www.fzrarchives.com/fzr600/600_m ... pt%201.pdf

Sorry Razor he's got a 1000 but what you explained works the same way on the 89-90 Ik's with conventional forks.

http://fzronline.com/wiki/lib/exe/fetch ... _89_90.pdf <-- Click here for the 89 1000 Manual and go to page 49 for an exploded view of the forks.

[reelrazor]

[
Sorry Razor he's got a 1000 but what you explained works the same way on the 89-90 Ik's with conventional forks.

Click here for the 89 1000 Manual and go to page 49 for an exploded view of the forks.

Yeah, geeez. I blew by that important detail, dint I? Thanks for the catch Sweekster!

[rmadursk]

Thanks for the replies. I tried undoing that bottom bolt with an impact but I couldn't hold on to it. I am going to put it in a vise with some rags around it and try that.

I saw the picture in the service manual but couldn't see how that bolt in the bottom was holding in the inner tube.

Going out to try it right now.

Thanks again,

Ron Madurski

[sweekster]

There's a damper rod that goes through the bottom of the top (chrome) tube and that is what holds it to the bottom half where the brake calipers bolt to.

Make sure to slide the seals on "number side up", which means spring side down.

I made the damper tool using a 5/8" threaded rod (3ft in length) and 4 nuts at each end. I put lock washers in between to hold them in place.

I made my"seal driver" from a 1.5 inch diameter pvc pipe-3 feet in length. Tape the seal end with duct tape so you don't damage the new seals. The pvc pipe will slip over the inner fork tubes perfectly and you can then use a hammer to drive the bearings and seals evenly. Got all the stuff needed for this at home depot for quite cheap.

[rmadursk]

That worked quite nicely. I got the parts cleaned up and ready to go to the powdercoater.

Thanks,

Ron

[Stumac]

aright razor,just been reading bout the subject above,dont suppose you have a pdf number for the fzr 1000 exup 91-93 manual do you,got a set of forks that i think have come of this,trying to get new seal sizes,oil capacities etc,cheers stumac

[tony]

http://www.youtube.com/watch?v=XhLo3V-sXKE