Rebound adjusters

[Swiss Toni]

I’ve ‘aquired’ a set of what I believe are 750 J/K or L forks. I’ve freed off all the pre-load and compression adjusters, but the rebound adj. on the top fork nut is solid! By the state it’s in, it’s been that way for a while. It’s mullered, and I might be wrong, but it looks as if it brass. The slot’s just about had it, so I don’t want to put an excessive amount of weight on it. Any ideas how to get it moving, or out altogether?

[Upshotknothole]

You'll probably need to disassemble it. Check the factory manual, it should show how to take it apart. I just checked, and to be honest, I'm fucking amazed, you can still get that brass piece from Suzuki.

 

[Swiss Toni]

@Upshotknothole it’s listed in the US as $30. I shudder to think what we’ve got to stump up!

[Upshotknothole]

5 minutes ago, Swiss Toni said:

@Upshotknothole it’s listed in the US as $30. I shudder to think what we’ve got to stump up!

Considering how many parts Suzuki has discontinued over the past few years, I'm just amazed that they still sell them. You could also swap the top off of a shagged fork as well if you happen to have access to one.

[E T]

@Swiss ToniI'm heading  over to states on Saturday for a couple of weeks, if you can get them over there I can give you address to send them to and i'll send them on to you when I get home.

[Swiss Toni]

@E TThanks for the offer! I’ll see what I can turn up here first, if I wreck them. 

[Lachie04]

Had the same problem and impossible to get em apart and no part available.

Ended modifying zzr1000 caps which worked well.

I did post some pics here but can't find em yet.

They need a bit of work and have to make a floating pin to meter the oil flow.

Will try to find some pics or the post.

Using these caps they are slightly larger thread so the cap threads need to be machined down also.

 

Edited August 10, 2023 by Lachie04

[Lachie04]

Just for interest sake a working drawing of the mod if all else fails and you want to keep the forks like I did 

 

I TAKE ABSOLUTELY NO RESPONSIBILITY FOR ANYONE ATTEMPTING TO TRY THIS

 

 

 

 

Edited August 10, 2023 by Lachie04

[Swiss Toni]

@Lachie04I’ll give the Ultrasonic a go first. Then a bit heat, if that doesn’t work. I like your solution though!  The rebound adjusters are still available in the US, don’t know about here. Not so, the compression ones. NLA! About time the Suzuki  Vintage Parts scheme got their finger out?

[Dezza]

Sometimes there are knackered (bent) slingshot forks cheap on eb@y. You can see where this is going assuming the caps are OK .

[Swiss Toni]

Well, @DezzaI’m a bit further along now, but it still doesn’t look promising. Called Robinsons this am, and both rebound and compression adjusters NLA. 

[Upshotknothole]

Have you tried removing the top from the fork? Strip it down as much as you can and let it sit in some penetrating oil? Maybe toss it in the freezer over night? 

[Swiss Toni]

Ultrasonic didn’t work. Stripped pre-load and rebound from top nut. I’ll drop them in some release all or some such, and see what happens. 

[Swiss Toni]

Both now residing in a cup full of release oil. Time will tell. 

[Swiss Toni]

Well, I’ve got them free! But, which way are they supposed to come out of the preload adjuster? They’ll only screw out a few turns, or screw in slightly below the top surface ... but that’s it! Won’t to right in, won’t come right out. Bugger!