Project 700ES

[reddirtrider]

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.........

Thanks,
Joe

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.

[posplayr]

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.

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.

I'll be more careful next time

[jwhelan65]

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.

[jwhelan65]

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!!

[Rkt-Rch]

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...

[jwhelan65]

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...

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..

[Rkt-Rch]

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.

[posplayr]

Joe,
At last for me this was about the time I realized working on Bikes is nothing like cars.
Glad you got them mostly apart; I had a fit with a pair of mine as well.
Jim

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.

[tejasmud]

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....


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....

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.

Just never know.

[Rkt-Rch]

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..

[jwhelan65]

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....


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....

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.

Just never know.

Oh believe me the addiction has transformed to obssesion and on to whack job! I polish little meaningless nuts and bolts daily and I dont know why???

[jwhelan65]

If yours is like mine was, you will be sanding and polishing until your fingers bleed. But yeah, worth it.



I think I'll paint the next one.

You could polish out a 3 foot piece of long chain to go with it and wear it around your neck...now that would be some serious BLING!

Very nice Bruce!

[cyclefvr2]

If yours is like mine was, you will be sanding and polishing until your fingers bleed. But yeah, worth it.



I think I'll paint the next one.

i think soda blastin would take care of most the hard work,then just polish

[tejasmud]

Oh believe me the addiction has transformed to obssesion and on to whack job! I polish little meaningless nuts and bolts daily and I dont know why???

Whew!!!! I thought I was the only one.

Now, if you drool each time after you begin picking up nuts or bolts off a parking lot, insisting the ones you find are all metric, knowing exactly where you are going to place it on you machine, and can't wait to get home to zinc plate and convert it, we will send the wagon and the nice white jacket.

[Rkt-Rch]

Funny thing, when it's down for repairs I start looking at parts and then, well I think we all know what comes next !!! I still have a couple days before the tank that got sealed goes on and the cleaned up coils with new (Purple) yes purple (Don't ask why) leftover HP Jet Ski Wire..

I wish I had my Die Grinder and Air tank in N.H. Left it in S.D. at Pops house.

The Die Grinder with a De-burring wheel is the best tool ever for polishing, I would have been done in a couple of hours, I did Various boat parts years ago (Jet Pump,manifold,alum wheels,etc..) used a clean De-burring to start, then one mixed with Mothers,Blue Coral,or what ever worked best at the time and well lets just say I miss my Die-Grinder... Time to go shoping... Humm I wonder If I can polish my fins on the Head,Front Anti-Dive fins thing a magigas.... LOL

I know you guys love pictures (Not suzuki)

Here is a picture of the Jet Pump.. (Before placement deverter and different headers,man,airscoop,etc.)