Hi Guys,

Currently have my 2000 ZX6R stripped down in my garage for a long overdue fork rebuild. All was going to plan until I tried to seperate the fork bottom from the stanchion. Tried undoing the allen drain bolt but the whole lower internals spin. I read somewhere I should have removed this when the fork is under compression so built it back up (minus the oil) and still spins.
Eventually I managed to remove it by putting a long screwdriver down inside the stanchion to jam the lower internal. A bit crude but it worked and doesnt seem to have hurt the inner stanchion.
My worry is when I come to rebuild the forks the screwdriver trick wont allow me to get a decent nip on the bolt and could cause damage.
Have any of you guys done this and what was your technique for removing the allen bolt/seperating inner and outer
According to a manual I have theres a special tool so is it a case of I need to find a garage who have the tool or could I manufacture something myself?

Please Help !

Cheers

I've only done dirt bike forks, and you remove the TOP on those ones. I did the same thing and tried turning the bottom, and the whole thing spun, when I unscrewed the top, the whole thing came off.

Did you check the manual in the file vault?

You may find this video helpful:

http://www.southbayriders.com/forums...ad.php?t=68310

It's how to replace the seals, but it shows you how to disassemble the fork.

LOL!!! i had the same problem with my 01!!! but, i improvised!!

go to the home depot and get a shower aluminum bar (about 3cm in diameter). this is the bar that your curtains hang on! Then bend the end of it to fit the elliptical nut on the piston housing on the inside of the fork.

It was harder for me because i had to come u with a toll while the internals were still inside the tube. now that you have the internals out, you can make sure the shower thing fits good (it doesn't really need to be strong because once you have the bottom allen bolt in, the internals will hold themselves so that you will be able to tighten it.

here is a pic to help you describe about shaping the shower bar. BTW, it can be any type of aluminum tubing, dont get the thick steel tube cause you wont bend it.

to actually bend it you could just hit the end of it on the pavement with the hammer to flatten it and then use pliers to shape it further

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cheers, ye i was tinkering today and thought if i could get a square piece of alluminium to slot into the internal part of the damping unit that should do the trick. (failing that the screwdriver may have to come back out lol).
I also have a heavy duty cordless with impact setting so may use that to tighten the allen bolt, might get away without holding the damping unit then.

Thanks for the advice!

How much oil does each shock take....anyone know?

And what about the nuts under the fork cap? Do they both get tightened up into the fork cap? I dont want to mess up the adjustments outside the shock.

Answered my own question....

Forks take about 15.4 oz of oil each.

The nuts get tightened both up to the fork cap.

Now how in the world do you get those pesky bolts at the bottom of the fork tube to tighten? Theres no way to hold the part inside from spinning. I heard you can use an impact gun, but you gotta be super careful. Any other ideas?

Thanks