If you've never done fork seals before this link will help,if you have the tools/Haynes manual for torque settings,10w fork oil is std grade & oil level from top of fork tube to oil is 121mm.
Does your brake lever have a ball on the end? if not then that's probably why advisory,the ball is there to stop your fingers from sliding off the end.
Hopefully the hesitation is just coolant running down the ht leads into the plug caps were they screw onto the ends.As you said you've been doing turns in/out of cones when you remove the fuel tank make sure that the overflow pipe under the radiator cap is there & is routed correctly.
I believe that the cylinder drain holes you speak about is the ones for the water that may collect when washing or rain & drains it away from the spark plugs/holes,so I think you may well have a coolant leak above your plugs,you will have to remove the fuel tank to try & find it.
Well that's sorted that then! I have never seen it come on & nor have you Fazer99, so I think we can safely say phil mcglassup that your overheating warning light doesn't either.
It's on the rev counter under 15000rpm marker. I have a 1998 model owners book does not mention the light should come on with ignition briefly only when overheating & the 2001 book doesn't either, but 2003 book says it should come on with ignition briefly. Just make sure the cooling fan is kicking in.
Make sure that you give the black pipes 3 iirc underneath the bike by the exhaust/center stand a good tug down whenever you remove or lift the tank or you risk getting a face full of fuel when you next undo the tank cap as pipes can get kinked.
Let the bike warm up then adjust idle down to 1200-1250rpm hopefully you should have a steady tickover give it a couple of blips on the throttle let settle & recheck idle speed.
Defo sounds fuel related as said,make sure your fuel tap is fully on under tank & make sure that you give the black pipes 3 iirc underneath the bike by the exhaust/center stand a good tug down whenever you remove or lift the tank or you risk getting a face full of fuel when you next undo the tank cap as pipes can get kinked. Draining the float bowls might help,by undoing the drain screws with a correct descent fitting screwdriver.
Just a couple of suggestions did you fully charge new battery before fitting & if you use the steering lock,did you turn the key to much anti clockwise & turn the parking lights on by mistake.
Has been previously posted so be sure to read this,but if yours are original bolts they will be plastic,maybe wise to get some new ones on ebay. http://foc-u.co.uk/index.php?topic=12863.0
Are you sure it's the forks & not the front brake pads knocking in the calipers,put the front tyre up against a wall & then try the forks with brakes off.
Not sure if they are the same but if it's the thundercat wheel I think you have seen it has the brake disc still attached & as you have found they can be a pain to remove,so I would get one with the disc removed already there are plenty on Ebay for FZS.
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