How To: Fork Seal Replacement on an '07 - Page 7 - 600RR.net
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post #181 of 190 (permalink) Old 04-01-2019, 08:46 PM
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add mine to the successful jobs done using this as a guide.

As for the adjusters having limited range after all was said and done, i have full range on everything. I ran all of the adjusters full soft prior to disassembly and then measured the lock nut to 10.8mm from the top of the rod (as per the manual) prior to reassembly. Everything worked well for me.

Although I did crack a plastic spring collar, so I was out $7 for a replacement.
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post #182 of 190 (permalink) Old 05-20-2019, 09:23 AM
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OK, so ive read thru this thread and have 2 or 3 questions. I just put a set of 05-06 forks on my 04.
Seals need changed so i got all the tools needed. fork seal driver and spring compressor.
Got everything apart no problem. I turned the rebound and dampening all the way to soft. Getting that spring compressed is a pain!
I pumped the rods to get all the old oil out and cleaned up everything.
Put everything back together in the order i took it apart. Well except i filled the fork with fluid and pumped the rod up and down a few times to bleed the air out.
I filled up the fork with 18oz of fluid. Installed the fork cap.
Now the forks are super stiff and dont compress. So stiff that when i hit the front brake the bike nose doesn't dive at all and the forks vibrate. ive got all the adjusters turned all the way to soft too.
I think i put them together wrong? Any ideas?

How much fluid does the fork require?/ whats measurement from the top? / is that with the spring in place? / where does the lock nut need to be set at before installing the fork cap?

Last edited by indfireblade; 05-20-2019 at 09:25 AM. Reason: added some items
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post #183 of 190 (permalink) Old 05-20-2019, 02:52 PM
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You must precisely measure the fork oil with a graduated cylinder or syringe accurate to CC....and pump your damper rod to get rid of air. Sounds like you put in way too much fluid. The service manual will have a spec for each fork leg.

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post #184 of 190 (permalink) Old 05-20-2019, 02:56 PM
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My manual says 413 ccs or about 14 oz but look up your specific year. If that's the case 3 extra ounces per fork will definitely cause that problem!

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post #185 of 190 (permalink) Old 05-20-2019, 03:13 PM
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Yeah Im thinking that too and also how far down is the jam nut(lock nut) supposed to be on the rod because i think it may have moved some.
anyway you can post a screen shot of the manual specs for the 05-06?
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post #186 of 190 (permalink) Old 05-20-2019, 03:16 PM
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Quote:
Originally Posted by Dirtydrew420 View Post
My manual says 413 ccs or about 14 oz but look up your specific year. If that's the case 3 extra ounces per fork will definitely cause that problem!

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i cycled the rod quite a few times to circulate the fluid and get the air out. Picking up the motion pro tool and definitely measuring this time. The measurement is taken with the spring out, correct?
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post #187 of 190 (permalink) Old 05-20-2019, 04:07 PM
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whats the air gap measurement supposed to be on the 05-06 forks?
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post #188 of 190 (permalink) Old 05-20-2019, 04:09 PM
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I've always measured the oil first then added it

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post #189 of 190 (permalink) Old 05-21-2019, 03:32 PM
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05-06 air gap (fluid level meaured from top of the fork) is 120mm?
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post #190 of 190 (permalink) Old 05-22-2019, 10:38 AM
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Quote:
Originally Posted by indfireblade View Post
05-06 air gap (fluid level meaured from top of the fork) is 120mm?
With stock internals I believe that is correct.

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