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Project 700ES

  • Thread starter Thread starter jwhelan65
  • Start date Start date
Nessism said:
Joe,

Just under that air collar there is a metal spring clip, it is just a piece of spring wire bent into a C shape. You need to dig that clip out before the forks can be pulled down and out. Once you have this clip out, the forks will pull down and out just like any other fork. There is no need to remove the risers, or fork cap.
Click to expand...
Not technically, but in the real world ... I've got a beer that says that's his problem. :dancing:
 
Got it ! I'll continue when I get home today.. I'm at work!!:(

Thanks guys!!
 
Got them off, thanks tejasmud! I loosened the the clip-ons and they wiggled free...seals next!
 
reddirtrider said:
The forks aren't indexed. They have a hole for the air and the collar the fits over them has a groove all the way around the inside to so that no matter what position the forks are in the hole isn't blocked. The collar is indexed to the top triple. There's a slot on the collar that fits in a tab on the top triple. You'll see it when you assemble them, it's hard to miss.

I broke down and bought the seal installation tool for the forks. If you need it let me know. It makes short work of those seals as they need to be driven in. It's also nice for installing the top bushing prior to the seals.
Click to expand...


I think I will take you up on the seal installation tool...sent you a PM
 
That is what I used. Can't be more than $5 for a 10ft stick at Homedepot or Lowes.
 
Joe Nardy said:
Joe,

Clamp the fork sliders in a vise and use the tubes as a slide hammer to pull the seals out. Be gentle but firm......... :D

Thanks,
Joe
Click to expand...
That's how you do it, but there's no need to be gentle. It takes a bit of banging to get them out. The top fork bushing should come with them.
 
reddirtrider said:
That's how you do it, but there's no need to be gentle. It takes a bit of banging to get them out. The top fork bushing should come with them.
Click to expand...

Depends if you are a whooze ;) or not.

I damaged the bottoms of my forks :( with too many blows.

My Gixxer forks came apart easily after I cut back the rubber on the seals and allowed them to soak a couple of days with penetrating oil. :dancing:

I'll be more careful next time :cool:
 
Got everything apart except for the left seat on top of the fork which is an issue. It really needs to come off to re-fill them, I was able to remove and salvage the discontinued clips but the left side is completely rusted shut.

Ordered all new clips, spacers, o-rings and dust covers where needed.

700forks4.jpg


700forks2.jpg


700forks1.jpg
 
Decided to strip and re-build the front calipers also while everything is apart...its never ending!....but plastic and the gas can is on the way!!

700frontcalipers.jpg
 
Good to hear that the parts are back or on the way. Just finshed sealing the tank last night !!! Adjusted the valves to .005 Intake/Exhaust while I had the valve cover off, was (WAS) going to polish it like everthing else but I think I don't want to waist the time, cant wait to get back on the rode. (my only bike) I'll buy one off e-bay and do it on my spare time... IT's going to be ALOT of work. Your VC came out pretty good, I plain on useing some High Temp paint (Silver) just wondering what type you went with ?

Oh yeah I forgot to say I will be doing the forks also (later this winter I think) but I'm glad i can refer back to this thread/post and have pictures already...
 
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Rkt-Rch said:
Good to hear that the parts are back or on the way. Just finshed sealing the tank last night !!! Adjusted the valves to .005 Intake/Exhaust while I had the valve cover off, was (WAS) going to polish it like everthing else but I think I don't want to waist the time, cant wait to get back on the rode. (my only bike) I'll buy one off e-bay and do it on my spare time... IT's going to be ALOT of work. Your VC came out pretty good, I plain on useing some High Temp paint (Silver) just wondering what type you went with ?

Oh yeah I forgot to say I will be doing the forks also (later this winter I think) but I'm glad i can refer back to this thread/post and have pictures already...
Click to expand...

Dupli-color Alluminun color engine paint on the VC, Forks were a little more challenging than I thought. The consensus on here is that fork seals are easy....I have a different opnion..:evil:
 
I think thats why all wait until winter season !!! Thats what type of paint you used... I guess we will find out how well it lasts to the heat.
 
Joe,
At last for me this was about the time I realized working on Bikes is nothing like cars. :o
Glad you got them mostly apart; I had a fit with a pair of mine as well.
Jim

jwhelan65 said:
Got everything apart except for the left seat on top of the fork which is an issue. It really needs to come off to re-fill them, I was able to remove and salvage the discontinued clips but the left side is completely rusted shut.

Ordered all new clips, spacers, o-rings and dust covers where needed.

700forks4.jpg


700forks2.jpg


700forks1.jpg
Click to expand...
 
Joe,

Doing a restore on a bike is like, well, quote Forest G on that one.

But, in the mean time it can, does, and will become an obsession, an addiction, a passion....... Perfection is obtainable....:p


Never know what you will need to do.

Seals are easy, if..............

you have done them on a few machines, sure. When they come apart. Stupid rubber caps with the round wire clips was not, I repeat not, a Suzuki innovative design.

I just got back from a friends house, we took 98 FZR600 headlights, and popped them into a 89 GSXR750.

I think.... :-s

The 89 GSXR750 I know, but....the FZR, late 90's I'm sure..

Anyways, they were the same for the most part, but were they OEM? Shoot they they fit. :D

Just never know.
 
OK I did it, I found a abrasive wheel that worked! Now I have to polish it (VC) It's comming out great so far, it's still going to take LOTs of sanding but I think it's going to be worth it. I'll make sure to take some pictures before I finish and also when I'm done..
 
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