04 gsxr front dampner rebound valve removal

[SLD]

Need help on the correct way to remove the front rebound valve out of the dampner rod in a gsxr 600 04.

Thanks
Sean

[GSXR RACER MIKE]

Need help on the correct way to remove the front rebound valve out of the dampner rod in a gsxr 600 04.

Thanks
Sean

     Is that a cartridge fork? If it is, it probably has what is labeled as a piston which is crimped around the damping rod somewhere apx. in the middle (the piston bottoms out into a 'cup' at the top of the cartridge). If this is what you have then you need to remove the piston by un-crimping it. The problem here is that if you un-crimp the piston you will need to then replace it with a removable one. Re-crimping the original piston will probably not be possible without special equipment, so be aware of this. The crimping is over a clip that drops into a groove around the outside of the damping rod. In order to un-crimp the piston you need to clamp the damping rod just underneath the piston in a vise with the assistance of a holder which will not crush the damping rod. If you do not have this holder you could very easily damage the damping rod. The area of the damping rod between the piston and the cartridge is vulnerable to scratches and dings, and will affect your suspension if damaged, so be very careful of that area. If you choose to remove the piston then you will need to drive the piston down the damping rod to spread the crimps. Great care must be taken in doing this! Once the piston is driven down it will expose the clip around the damping rod, this needs to be removed. Once the clip is removed the piston can be slid off of the damping rod which will allow the damping rod to slide thru the cartridge and out the other side once the compression valve has been removed.

     I hope this helps, but be very careful if your not familiar with doing this. :)