Fazer 1000 Suspension woes and more

[unfazed]

Cheers for the replies fellas.
Thanks for the settings Unfazed, I was around those already as I think that feels the best with how it is.
Yep I changed the fork Oil (5w) when I got it, it was fairly old but not the worst ive seen. I need it for a stint in euope in about a months time, by the replies I think I will go straight to fully splitting them with new bushings then.
How hard is the damper rod on to remove on these, ive diy'd a tool before on simpler forks but this looks a bit more complicated inside.
If lack of oil changes causes internal wear im wondering if my forks have already been damaged then. I noticed this too when I was changing the oil.
https://puu.sh/DH7dJ.jpg
Roughly how much did it cost for a rebuild from MCT? Spings, new hardware etc.
The main problem is still a constant juddering and bucking through the bars, even on fairly smooth tarmac. Its not that the settings are a little soft/firm, it just feels like something is fundamentally wrong/broken on them.

Before you start write down the number of clicks back from full hard you have set on the rebound adjuster.
The damper rod is easy to remove, but needs a 26mm socket, It does not require much to hold in in place while loosening the bottom bolt. I used a 3/8 drive 26mm socket duct taped to a straight length of chrome vacuum cleaner pipe. Held it by hand with nitrile gloves on.  Same putting it back in, getting everything to line up was the slow part.Follow the instruction on the Haynes manual which are very good.
Wrap the threads of the upper damper rod with a split piece of petrol pipe and hold it with a vice grip to undo the nut all the rest is easy enough.
Note: Before refitting the rebound adjuster; Set the rebound adjuster half way on its adjustments, it has 42 clicks when of the forks, but only 21 are used from full hard to full soft.
When it is all back together wind the adjuster to full hard and back it off to your settings. Now you can be sure the adjuster is set to full hard not the end of adjustment before full hard is met. That ensures that both dampers are equal. Many put the adjusters back as they come off, but that can end up with both sides different and almost impossible to set the rebound correctly.

Before You strip the forks, check the following:1. The bearings are not worn. (Check this with the calipers off the discs and tied up)
2. The rim is straight
3. The tyre is on straight4. The wheel is balanced5. Headrace bearing are not tight or notched