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Old 11-25-2006, 06:10 PM   #1
bumblebee
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Rebuilding USD forks

I have a '04 GSXR 750. One of the forks has started leaking. I have rebuilt regular forks but am a little unsure about USDs.
Also I was told when I bought it that it has traxxion dynamics at20 internals, will that make a difference? What weight fork oil?
Any references from a service manual or links to websites would be helpful. Even personal experiences would be great.
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Old 11-25-2006, 06:21 PM   #2
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10 weight fork oil. If you have done conventional forks you shouldn't have any problem. they are pretty simple really. If you have any questions give me a call.
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Old 11-25-2006, 07:11 PM   #3
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According to my Suzuki manual it's 5 weight, it's the same in my Traxxion manual.

You'll want to measure the fork oil height, with the cartridges in, but springs out, forks fully bled and compressed.
The height you're looking for is 110mm, from the top of the tube, fork compressed to the top of the oil.
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Old 11-25-2006, 07:18 PM   #4
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Also while you have it apart, make sure you clean the cartridges well.
Don't forget to set your rebound height correctly.
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Old 11-25-2006, 07:24 PM   #5
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Quote:
Originally Posted by Patrick
According to my Suzuki manual it's 5 weight, it's the same in my Traxxion manual.

You'll want to measure the fork oil height, with the cartridges in, but springs out, forks fully bled and compressed.
The height you're looking for is 110mm, from the top of the tube, fork compressed to the top of the oil.
Well my manual says 10wt and 3.9 inches from the top in my clymer and my suzuki tech book I just checked too.
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Old 11-25-2006, 07:26 PM   #6
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Quote:
Originally Posted by TLLuvr
Well my manual says 10wt and 3.9 inches from the top in my clymer and my suzuki tech book I just checked too.
3.9 inches is not equal to 110 mm so ...
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Old 11-25-2006, 07:29 PM   #7
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The 05 calls for 5 wt according to my manual. 01 to 04 calls for 10 3.9 in from top as well as the 05 but isn't that more like 390mm
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Old 11-25-2006, 07:30 PM   #8
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Quote:
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The 05 calls for 5 wt according to my manual. 01 to 04 calls for 10 3.9 in from top as well as the 05 but isn't that more like 390mm
oops 156 mm I think.
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Old 11-25-2006, 07:52 PM   #9
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Sorry I must have missed this day in class 3.9" is 99.06mm. The weight of the oil is not nearly as important as having the correct amount. I have two books here that say one thing and Patrick has two that say another, sorry I hope we haven't just added to your little dilemna. I don't know which book is right but I will find out for you asap.
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Old 11-25-2006, 08:09 PM   #10
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If it has Traxxion internals go with 110mm, and I'd recommend the same if it was stock.
I'm not going to get in a match on fork oil weight or height.
Both make a difference.
I would venture to say that I've probably built over 100 '04- '05 forks in the last 2 years.
BTW, if the manual says US1 it's referring to 5 weight.
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Old 11-25-2006, 08:25 PM   #11
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I didn't say one didn't make a difference I only said the proper amount is more critical then the weight, you can change the weight but you wouldn't want to change the quanity would you? This is no match I only gave him the info in my suzuki manual and you felt the need to correct me. I was only trying to help.
btw it says 10wt not US1
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Old 11-25-2006, 08:29 PM   #12
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Touchy aren't we.
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Old 11-25-2006, 08:42 PM   #13
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and so it begins............
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Old 11-25-2006, 09:12 PM   #14
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Touchy aren't we.
Not in the least I don't worry about competition.
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Old 11-25-2006, 09:13 PM   #15
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Good.
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Old 11-25-2006, 09:31 PM   #16
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Thank you for your input. I've decided to install grease zerks and just pump them completely full of general purpose bearing grease.
It's so much quicker and easier. Plus I don't want to start any conflicts. :icon_bigg
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Old 11-25-2006, 09:33 PM   #17
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I definitely would recommend the heavy axle grease!!! :laughing6
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Old 11-26-2006, 12:26 AM   #18
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No definently use Hypoid gear oil!!
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Old 11-26-2006, 12:36 AM   #19
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Touchy aren't we.
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Old 11-26-2006, 12:42 AM   #20
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Quote:
Originally Posted by bumblebee
Thank you for your input. I've decided to install grease zerks and just pump them completely full of general purpose bearing grease.
It's so much quicker and easier. Plus I don't want to start any conflicts. :icon_bigg
I think Mil Spec 5606 would work better (cheaper) in your case! :laughing6
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