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FZS600 / Re: HOW TO: Forks Seals, Bushes and Oil
« on: 27 May 2020, 11:51:54 am »
hi, thank you for the above tutorial, a fantastic resource for all. i followed it yesterday to replace my blown fork seals, FZS600 1999
there is something significant the tutorial does not mention which gave me a real headache for a few hours, im not sure it is due to the fact the one in the tutorial is a slightly newer foxeye model.
there is a small white plastic spring loaded tube called a spindle taper(alluded to by Jamieg285) which sits right at the bottom of the lower/outer of the fork, this has a habit of jamming into the inner/upper fork, if this happens you cannot refit all the internal parts as it becomes impossible to close the cap bolt.
you have to drop the spindle taper into the bottom/outer fork first and foremost, then to add the bottom damper retaining bolt you need drop the damper unit into the upper/outer fork and slowly lower it in without bottoming out and not catching the spindle taper, torque to required amount, you can then add all the spring/spacer etc before adding new oil and top cap.
as i mentioned you cannot let the let the inner/upper fork drop all the way down whilst fastening the bottom damper bolt as it will catch the spindle taper making assembly impossible, hope this helps.
there is something significant the tutorial does not mention which gave me a real headache for a few hours, im not sure it is due to the fact the one in the tutorial is a slightly newer foxeye model.
there is a small white plastic spring loaded tube called a spindle taper(alluded to by Jamieg285) which sits right at the bottom of the lower/outer of the fork, this has a habit of jamming into the inner/upper fork, if this happens you cannot refit all the internal parts as it becomes impossible to close the cap bolt.
you have to drop the spindle taper into the bottom/outer fork first and foremost, then to add the bottom damper retaining bolt you need drop the damper unit into the upper/outer fork and slowly lower it in without bottoming out and not catching the spindle taper, torque to required amount, you can then add all the spring/spacer etc before adding new oil and top cap.
as i mentioned you cannot let the let the inner/upper fork drop all the way down whilst fastening the bottom damper bolt as it will catch the spindle taper making assembly impossible, hope this helps.