Hi, it's Danny (Bicycle Repairman)

[Bicycle Repairman]

My first Yamaha was a 1980 XS850 Midnight Special the previous owner had installed lower bars and a bullet fairing. I wish I still had that one.

The current project is a 1995 FZR1000 EXUP with 162 miles on it. It was "stored" (neglected) for 28 years. During the year it sat (neglected) in my garage, mice had filled it with dog food and damaged some of the wires. Long story short, the last thing before it's like a new bike is fork seals but I don't have 1995 manual/supplement to tell me the factory air space/oil lever for the KYB USD forks. I assume compressed with springs out. Anyone?

Thanks, Danny

[Snakebite68]

Trust this at your peril...

 

After a quick 2min google search:

Capacity: 425 cm3 (15.0 Imp oz, 14.4 US oz).

Oil Level: 143 mm (5.63 in) From top of inner fork tube Fully compression without spring.

Grade: Fork oil 10WT or equivalent.

 

If that means anything to you.
Taken from the 1987 FZR1000 service manual

[Bicycle Repairman]

Thanks for trying. The '87 fork is completely different. '95 was the first year the KYB USD (upside down) for was used. I have a manual for earlier models but not the '95 supplement. Hours of scouring the interwebs has turned up nothing. 

[NE0]

Welcome Bicycle repairman,

This info any good to you , far right fork capacities for 94 to 96 FZR1000 EXUP

https://www.louis-moto.co.uk/en/bike-database/yamaha-fzr-1000-exup/3le-94/0593?back=&categoryKey=ROOT&ipp=48&page=1&sort=name_asc&viewMode=grid

 

OR Better still....

Forks Info for YAMAHA FZR1000 1995

 

KYB USD 41 mm OD

Compression Nut Torque 30 in-lb (0.35 kgf-m)

Fork Travel 88 mm

Front Sag 37 mm

Preload Adjuster 0 mm Range

Fork Oil Weight SAE 10

Fork Oil Level 140 mm

Oil Quanity2

Standard Preload 20 mm

 

from this page....

https://www.teknikmotorsport.com/complist/yamaha/fzr1000/1995/

[Snakebite68]

Interesting, everything I'm finding is that the FZR went out of production in 1994...

[drewpy]

in btw

[Bicycle Repairman]

I believe 1995 was the last year.

Thank you, Neo! That's exactly what I needed.

I'm not sure what "Preload Adjuster 0 mm Range" means though. My forks have adjustable preload.

[NE0]

I would say "Preload adjuster 0 mm Range", suggests( and i'm no expert) that it's wound to its stop for the level to be taken, then wound out to 20mm standard preload.

Thinking about it, I believe its just stating that all the readings are taken with the preload set to zero: for the travel to be 88mm and sag, well....that's my interpretation of it, but i don't have it in front of me, however, i think its going to be something on those lines. It's just a reference point for all the specification figures to apply.

[Bicycle Repairman]

If I'm interpreting correctly, the level is measure with springs out, stanchion collapsed and adjuster full out. (0 mm preload)

[Bicycle Repairman]

I finally found a downloadable service manual that covers the 1995 with the KYB USD fork and figured out how to free the spring from the damper rod. Of course it requires a special tool that can easily be improvised with some plastic pipe and a washer but since the seals can easily be replaced without disturbing the spring, I decided to simply wash everything with Maxxis Suspension cleaner and call it good. Rather than using air space to measure oil, I used volume. I put in slightly more than 16 US ounces in an effort to stiffen the compression a bit. I also used 15W oil.

I won't bore you with all the work, time and money I put into this project but it was a fight at every turn. Now the bike that had been "stored" for 29 years with 162 miles on the odometer, now has 168 miles on it. Tomorrow, much more!

https://www.facebook.com/bicycle.repairman.75/

[NE0]

Nice one Danny, Glad you got it sorted, now you can clock those miles up.

As a reward , here on the site we have a badge system, the more votes you get, progresses you up the ranking, it's only for fun! nothing elitist or special about it!!

You can even get on the leaderboard for post of the week, gold silver and bronze

On the bottom right of a post there is a grey heart (gray as you're in the US) you simply click on it to give someone a thanks etc, these likes put you on the leaderboard on the top right, the more you get contibutes to your profile.

so I'm going to start the ball rolling and like your posts etc. and you'll see your name on the leaderboard!!

All the best

NE0

 

[Bicycle Repairman]

So the next day I rode it to our local moto enthusiast hang out here in Tucson, Gear Shifters, and the owner immediately invited me to submit it for curation in the 520 Moto Show presented by  Iron Horse Motorcycles (shameless plug). I didn't have to think about that too long. It now has a little over 200 miles on it! I think the fueling is not quite right though. The pilot jets are for Portland elevation around 400 ft. give or take and i'm now at over 2200 ft. Or maybe the fuel pump is gunky or maybe the fuel filter is gunky. In any case, I still have some fueling issues to work out. Other than that, I feel a rock star riding it!

 

I finally found a downloadable service manual that covers the 1995 with the KYB USD fork and figured out how to free the spring from the damper rod. Of course it requires a special tool that can easily be improvised with some plastic pipe and a washer but since the seals can easily be replaced without disturbing the spring, I decided to simply wash everything with Maxxis Suspension cleaner and call it good. Rather than using air space to measure oil, I used volume. I put in slightly more than 16 US ounces in an effort to stiffen the compression a bit. I also used 15W oil.

I won't bore you with all the work, time and money I put into this project but it was a fight at every turn. Now the bike that had been "stored" for 29 years with 162 miles on the odometer, now has 168 miles on it. Tomorrow, much more!

https://www.facebook.com/bicycle.repairman.75/

[Snakebite68]

Congratulations!
Well, the main thing is that you have fun riding it..

[increasing]

Welcome