www.zxrworld.co.uk

Anyone got any tips to get to the nut at the top (under the top cap without a spring compressor?)

Last time I did one with a friend we had a proper spring compressor, I've had a look on Youtube but most of the vids on there are either using the 'special tools' or they're off-road shocks which are completely different.

When I did mine I made a special tool. Just got some planks of wood and threaded rod from b&q. When you've winded it down far enough, clamp it with some mole grips so you can get the top plug back on. I'd be careful if you're 'improvising' as the last thing you'd want is to slip/ something to break when the fork is fully compressed.

use an open ended spanner to compress the spring whilst undoing the nut

I'm trying to work out how your one in the pic works there

What holds the cartridge? The hole in the top piece of wood isn't big enough to get the top plug through?

Did think about getting a spanner in there but can't get anything that will fit? It looks like a tiny (3mm or so gap with 3 or 4 tiny colums that hold it aware from another plate (creating the small gap) if that makes sense. Only way of pulling it down on these forms seems to be in the holes on the cartridge?

I was looking at possibly making something like this:
http://www.sv-portal.com/forums/showthread.php?t=33753

EDIT:
Just wondering if you undo the allen bolt at the bottom in theory will that let the two halves separate without taking the top cap off of the centre rod? Just looking at the exploded view in the manual.

I tied some string from the rod that the top plug goes onto, to the roof of my shed. This stops it from falling down into the fork (so you don't have to hold it). The hole in the top is big enough to allow the rod/ string to go through, but small enough to stop the spring going through (because you want to compress the spring but not the rod).

The mole grips were placed between the spring and the wood with enough space between the claws to get the rod nut through, so that when you've compressed the spring enough to get the grips underneath the rod nut, you can tighten the grips which holds the spring below the nut. You can then undo the top plank of wood enough to get the top plug on. Then just carefully remove the grips.
It's harder to explain than do in practice lol.

Yep I get what you mean, doesn't that only give you the means to get the top plug back on though?

How do you get the wood under the top plug to be able to compress the spring down enough to expose the nut so you can put a spanner on it and undo the top nut?

Oh so you're trying to dissmantle the forks? In that case yea you can just undo the top plug from the outer tube, and the allen bolt at the bottom. You can then just slide the internals out.

Ah ok.. I did wonder if there was going to be an easier way

I guess I need an impact driver on the bottom as the internals will just spin otherwise?

I was a bit confused as all the procedures I've seen on the web say to take that top plug off, but I was sure you could just undo the bottom to get to the seals.

You might not need an impact driver to undo them, but depending on which way you re-build them, you might need it when doing them back up.
There's a useful guide here: http://www.zxrworld.co.uk/zxr400/forks.html
And also the 'proper' way of doing it: http://www.zxrworld.co.uk/Manuals/L%20M ... r%2012.pdf

and don't foget these 2 guides

viewtopic.php?f=55&t=6035

viewtopic.php?f=55&t=9037

Cheers guys, think I'll go with doing it that way round.

Just 2 Questions using this method...

From memory (and what I read in the manual earlier) aren't you mean to fill the fluid level up with the spring removed and the unit fully compressed? If so did you guys just make sure all of the oil was completely drained from the inner cartridge and outer parts then fill with the 424ml of fluid? I'm sure when I tried doing it by measurement last time I ended up with way too much in there so had to revert to measuring the 85mm I think it was down from the tube top which of course will be wrong as the spring is in there pushing the fluid up?

and...

What stops the internals spinning when you do the allen bolt back up? Or does the pressure of compressing the spring hold it all in place.. not sure if I'll be using a fence post though baz .. 'Bizarre ER - This week, Male 29 impaled with ZXR400 shock through forehead'

Measure the amount of fluid you remove and add the same amount again. Assuming its right now you'll get it right again.

Afraid quite a bit leaked out, I guess in theory the other side should be ok and will be changed at the same time.

Always wondered why instaed of saying xxx ml it always has +- so many ml, what is the variation for? It's not like there is a service limit on fluids?

See this thread. viewtopic.php?f=7&t=9389

I have tried them all and got sick of the dicking about with tensioners etc.

The method in the manual needs 2 special tools although in reality only one is really needed (the spring compressor). the rod puller could be achieved with wire.

All other methods are either pretty risky or compromise the quality of the job in that filling with oil to the same quantity as removed depends on the oil in the fork being initially right which is a big assumption,

The compression tool sits on the top of the nylon bushing and therefore allows the spring tension to be applied and released in a controlled manner when the top valve has been torqued onto the rod.

Applying all of this is a two man job as one compresses/ releases the spring while the other either traps or releases the holder (whatever you use for that) from under the rod nut. This techniique allows accurate oil filling etc

Speedy wrote:
If so did you guys just make sure all of the oil was completely drained from the inner cartridge and outer parts then fill with the 424ml of fluid?

thats how i did it, too much mess trying to do em with half the oil still in the forks.

speedy wrote: What stops the internals spinning when you do the allen bolt back up? Or does the pressure of compressing the spring hold it all in place.. not sure if I'll be using a fence post though baz .. 'Bizarre ER - This week, Male 29 impaled with ZXR400 shock through forehead'

sometimes you can be lucky and get away with it, i had a right game so improvised and yes the fork through the forehead did cross my mind or losing my hand.