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Project My 96 Suzuki Across

Discussion in 'Your 250cc Projects' started by murdman87, Jan 6, 2016.

  1. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Get a professional to do it. Those kinds of forks are 'easy'

    Otherwise, be prepared to get very dirty and deal with disgusting smelling fork oil.

    You need a way to raise the front end of the bike. Remove the wheel. When I did the forks on my R6, I zapped the damper rod bolts on the underside with the top caps still in place and let all the oil drain. Lifted up the dust caps, removed the circlips holding everything in place and yanked the bottoms out. Replaced the bushings, seals and circlips, refitted & zapped the damper rod bolts back in.

    Then I just undid the fork caps and filled them with the specified amount of oil, bounced them up and down a few times after doing up the caps. Job done.
     
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  2. Cbuzz

    Cbuzz Well-Known Member Dirty Wheel Club

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  3. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Yamaha's , 1990 FZR250R 3LN3 , 1986 XT250TS 57R , 1984 IT200L 43G, 1976 IT400C 510
    When i did the fork's on my FZR250R i just slung a rope over a rafter on my back verandah and tied each end to my handlebar's to hold the front wheel up off the ground.
     
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  4. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    I used two cheap ratchet straps.
     
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  5. Jethalter

    Jethalter Well-Known Member

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    I did this when i did the twin discs on the across and rebuilt the forks at the same time, donor was by the rafters and my main across was by engine crane.
    I also had to use a nut welded on a rod to undo the bottom bolt in the forks whilst rebuilding.
     
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  6. murdman87

    murdman87 Well-Known Member

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    Cheers for all the info guys good stuff.


    Redone the cover on my seat today. Bike looks brand new. 20190306_175848.jpg As it was with the tape holding it together removed.

    Undid all the staples and used $10 worth of textured heavy duty vinyl from spotlight with the end result looking like this:
    20190306_195525.jpg
    I think it looks bloody brilliant and only took a bit over an hour and a half start to finish.
    Well worth it.
     
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  7. murdman87

    murdman87 Well-Known Member

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    Picked up a new project bike today, it's just a little bigger than the across.
    20190324_172427.jpg
    So the little across is up for sale so I can work on the big bike. Got it for a good price and hopefully I'll enjoy riding it as much as looking at it
     
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  8. murdman87

    murdman87 Well-Known Member

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    The little across is now sold, and I can focus on my new project
     
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  9. kiffsta

    kiffsta Senior Member

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    Congrats mate , they can be hard to part with, but at least you already have your next bike
     
  10. murdman87

    murdman87 Well-Known Member

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    Yeah I will miss it, was a lot of fun from start to finish.
    Went to a young bloke on his Ls with big plans for it already
    But I got the other bike cheap enough that it was basically a straight swap with a few extra steps. So I'm keen for the new one!
     
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