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Discussion Starter #1
Had my fork seals replaced only recently and within a week the right side seals are gone.......I'm not sure what is causing this, looked around and it seems the quality of fork seals and poor workmanship are two most common causes.
I'm not now going to spend another lump of dosh to the mechanics again and looking to do this myself. So gathering information now as I think I will try to do an upgrade whilst I've my forks removed. So here are a few questions

  • Cartridge kits - does 2003 model use these ?, if I buy an aftermarket cartridge kit, will it fit 2003 model forks ?
  • I've seen replacement springs rated 9.0n, 9.1n etc - I weigh 110kgs/17.5stones/242 pounds - so what rated springs should I be getting if one exists for my weight :crackup:
  • What is revalving and how does it help.....is it something I can do myself with the right tools, or does in involve drilling holes with precision machines etc ?
  • I see references made to 20mm/22mm/30mm kits etc....I assume these relate to cartridge kits and not connected to 2003 fork internals...am I right ?
 

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Fork seals are relatively easy if you have some mechanical inclination. Life is easier with the right tools (spring compressor, etc..). Cartridge kits are drop in replacements for your entire damping system. Yes 2003 has a cartridge inside the fork. Depending on what youre using the bike for, this is usually not necessary. You can make the stock suspension function for your weight and purpose.

Check out this link (specifically, post #26):

http://www.600rr.net/vb/showthread.php?t=190075

Theres a racetech link that will help you figure it out.

Revalving is replacing your compression/ rebound valves to functionmore efficiently. Youll prob want to do the valves. Reason being, when you put such strong springs in (consdidering your weight) the stock valving will be ineffective making your forks more like pogos. This is not a "do it yourself" job unless you REALLY know what youre doing.




This ALL depends on what youre using the bike for.
 

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The 03 has conventional forks. You need to talk to a local suspension expert. Make sure he knows your forks are conventional.
 

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are you doing wheelies?

any signs of scratching, pitting, marks or mars on the shiney part of the forks?
 

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If you just want to do the seals, do that at home...

But if you want to go increasing the spring rate then as Bullast said, you will need to have them re-valved to suit and that is best done by a professional. Just make sure you take it to a specialist and not your mechanic or dealer, if you have a race shop nearby they will be able to point you in the right direction.

If you can get in there and have a look at the shop you want to see something that is about as clean as an operating theatre... if they are meticulous about that then they should be just as careful with your bike.
 

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Those were going to be my next questions tenjin. At his weight, if he is doing wheelies, it'll easily over pressure the forks.


OP,

Where do you live? Search for GMD in your region.
 

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Discussion Starter #7
I'm not doing any tracks at the moment, but there are some real fast roundabouts near where I live and just having a go around them all the time tbh in my slow effort to see if I can get my knees down at some point...the bike can do it I guess, but I still haven't built up enough confidence in my abilities yet !!
I'm not doing any wheelies, never tried, never interested......, going around the corners fast is all I'm interested and hence the desire to get my suspension sorted.

Thanks guys for the tips, I think I'm going to tackle the fork seal replacement myself and then play around with the settings to see if I can make that work for my weight.

No suspension shops near where I live, but end of June there is a track day happening at Brands hatch(UK) which is about 10miles from my home and there is going to be suspension workshop there by "100% Suspension", will take my bike down there and see what they can do.

Any suggestion on what weight fork oil I should be getting for my weight to be used with the standard internals.....and what is the weight of the standard fork oil btw ?
 

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in my slow effort to see if I can get my knees down at some point...

Getting your knee down is ABSOLUTELY NOT a measurement of skill! This is a common misconception. There are many other elements that come into play that make you faster, not just more lean angle.
 

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Discussion Starter #9
I do agree to some level that knee down alone is not going to make anyone faster....but it is a given fact that getting your knees down is the most scary thing for anyone trying to go faster and most essential to master and gain confidence upon if intending to go at some decent speed in a track at some point. Hence the mention about knee down thingy.....I remember when I used to have a Honda hornet and one of the members in a hornet forum gave me the below lesson on getting my knees down

" Stop the bike and put in on the stands, get down, bend your knees and kneel on the floor, waalllaaa both knees down...job done....now get on with your life"

Not sure why that comes into my mind now, but it was real funny :)
 

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Discussion Starter #10
btw...is it possible to remove one fork at a time to replace the fork seals...I mean without having to take the entire front end off, can I remove one fork do it up, fit it back and then remove the other one and do the same. The reason I'm asking is because i dont have a centre stand or a jack to support the bike, so I'm thinking the above if it will be safe and the bike will manage to stay upright with just one fork supporting the front wheel ?......it might all sound silly, but I'm trying not to spend more money buying car-jacks etc. thanks.
 

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Nope, you need to remove the axle, at which point there is nothing keeping the front wheel there....
 

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Ive seen guys suspend their bike from rafters/ceilings with ratchet straps wrapped around the upper triple tree.
 

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Ive seen guys suspend their bike from rafters/ceilings with ratchet straps wrapped around the upper triple tree.
and large ladders...
 

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Discussion Starter #15
turns out my car has a jack.....so I'm gonna place it under the downpipes with a piece of wood(here comes the chopping board from the kitchen....I need to use it as well at some point right :0 ). I've also got some nylon ropes, gonna tie the upper triples to the rafters in the garage for additional support....not gonna use the rear paddock stands. Had a look around the bike this evening, it appears I dont have to remove any of the fairings to take the forks out, once the brakes calipers are undone, and the pinch bolts loosened, it should just slide out I guess.....any comments on this ?...thanks
 

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Spot on... have a look at the cct replacement thread in my sig, has a few pictures in there. And if you have a rear stand, use it.
 
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