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You have to buy the washers in a 50 pack for the small ones and a 5 pack for the big ones. If you're in the us and send me your address I'll send you enough to do your bike. I'll just put them in a regular envelope and send them through the normal mail.

I used the McMaster carr stuff that people posted part numbers for and it worked just fine. Its 2 big washer, 1 for each side of the wheel and 4 small ones, one between for each caliper bolt between the fork leg and the caliper.

Quick update: So after searching around on facebook marketplace I found a killer deal on a set of 03 r6 forks and brakes. Did an all balls tapered head bearing conversion while it was apart. Just got it mostly wrapped up today minus flushing the front brakes and my r6 axle comes in friday (I...

Anyone currently making the spacers for the axle and calipers to do the 03-04 r6 fork swap??

Yeah theres another shop nearby, they kinda specialize in dirtbikes but work on everything. I know hardcore offroad guys are constantly changing out fork oil and rebuilding forks so I'll give them a shot.

The worst part is I took them the forks already removed from the bike lol.

Thank you to everyone that helped out, I really appreciate it. I'll update after I take it back to the shop. They are closed on mondays, hopefully they dont get shut down from the craziness going on before then. Thanks again everyone,

And I'm not overly shocked, they are a good ole boy vtwin type shop but they are local and reasonable rates. They redid the seals on my old 07 fz1 a little bit back and I was telling my wife I was a little worried because fz1 forks are a little more complex then harley forks haha but they turned...

Sorry I'm being a pain, I've rebuilt a few mtb forks but never had a motorcycle fork apart

Not installed correctly or bad?? Is it the one that comes out with the seal or is there another one??

Left (clutch side) fork leg is the one bottoming out. Other side slides almost to the lower triple clamp. Its stops with a solid, metal on metal sound. Any ideas were to go from here??

Still bottoming at just under 2.5 inches even with the internals removed from the fork. I'm gonna pull the wheel and front fender and do each leg individually, I'll report back

Ok fork is apart, all lengths match up. I did notice that the springs wer upside down, tight wound part was at the bottom, I wouldn't thank that would be the problem though. I'm getting ready to cycle the fork with everything out and see what kind of travel I get

So when I pull the cap off I should find a spacer, then a washer, then the spring in that order correct?? Is there anything else under the spring?? Anything else I should be looking out for that could be the problem besides the lengths of the spacers and springs??

That's great info to have for when I tear into it, thanks alot

Great idea, maybe I'll do that tomorrow

Thanks for the ideas guys, I really like the air assist idea, my center stand is removed but I did put it on the side stand and rock it over and lift up on the bars so I think the fork was fully extended when i took my measurement.

Hello everyone, brand new here. I just picked up an 04 fz6 and riding it home it was bottoming out the fork badly. The seals were junk so I had a local shop change out the seals and refill with 10w oil. After getting the forks back and reinstalling them it's still doing it. I put a ziptie on...