my 650csr's transformation to the "RAT RACER"

CrazyDuck wrote: Good god. I have never seen a set of forks leak THAT much before.

martin_csr wrote: Install seals that are made in Japan, such as K&L - not sure what Z1Enterprises sells now.
Some dealers apparently install cheap aftermarket seals (ie, made in china etc).
After rebuilding the forks, air them up to ~8 psi w the front wheel off the ground... the useable range is ~7.5-14 psi or thereabouts. Use a low pressure gauge, not a typical tire gauge. Do not air them up to the max listed on the forks.

martin_csr wrote: A bicycle pump works. 10W fork oil is specified, but 15W might be preferable.
Use an air impact gun & a hardened 8mm socket allen to remove the bottom allen bolts. You may have to heat them w a propane torch. If they're stuck &/or the inner cylinder (damper rod) spins w the allen bolt, then you'll need to make a tool to keep it from spinning. The head of the damper rod looks just like a 19mm socket. I used a short 1/2" left-hand-threaded bolt w nuts (a 1/2" bolt has a 3/4" head which ~=19mm).

martin_csr wrote: Yes, relieve the air pressure. Also, you could try draining them by removing the drain screw at the bottom, but it seems easier to remove the top caps & dump out the oil. I dumped it out without removing the innards, then poured in some lacquer thinner, inverted a few times, then dumped that out & proceeded w the disassembly. It's a messy job but the solvent makes it less so.

martin_csr wrote: Yes, relieve the air pressure. Also, you could try draining them by removing the drain screw at the bottom, but it seems easier to remove the top caps & dump out the oil. I dumped it out without removing the innards, then poured in some lacquer thinner, inverted a few times, then dumped that out & proceeded w the disassembly. It's a messy job but the solvent makes it less so.