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Old 12-11-2012, 04:08 PM   #1
Join Date: Jun 2011
Bikes: 2009 Yamaha R1
Location: Detroit,MI
Posts: 84
suspension rebuild

Can anyone tell me where I can download a video of how to rebuild the 09 forks? Can't find the Dave Moss video?

I plan on installing new springs & revalve. Has anyone done it before? (DIY)
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Old 12-11-2012, 09:12 PM   #2
if ya cant dodge it, ram it
shane125l's Avatar
Join Date: Oct 2010
Bikes: 09 r1
Location: Edmonton, AB
Posts: 596
Graves has a youtube video of their guy servicing josh hayes forks. I donno if that helps

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Old 12-12-2012, 02:34 AM   #3
kickin' at the darkness
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Bikes: 2005 RAVEN R6, sold; PEARL WHITE 2009 YZF R1 ~ rip, CADMIUM YELLOW 2009 YZF-R1!
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yup, i've done it... at least the springs, i am doing the re-valve this winter...

I have a buddy who is a machinist and has helped me in building the tools I required, as there are several
so it has been really easy... you will definitely need a yamaha made damper rod holder tool in order to get
at the valves, i believe the part number is listed in the yamaha service manual {page 4-60 to 4-70}... also in order to open up the bottom
half of the forks you need an Ohlins tool {cylindrical jaws which hold fork lowers in place} so you'll probably have to take it to a suspension shop as it has to
fit perfectly around the lower fork {inner tube} while you unscrew the cast 'feet' {for lack of a better word haha},
yamaha chose to use a crapload of loctite on these so they'll have to {note the circled area in the pic attached}
heat the axle cast {black parts} with a hand held torch, and thus melt the loctite this way and enable you to unscrew
cast feet from the {inner} fork tube.. i hope that makes sense... lol

at the time i was doing this there was very little info available so we just had to figure it out ourselves,
i cant tell you how many pages i browsed trying to figure it out and in the end i just gave up and went
at it... thankfully both my buddy and I are pretty adept at taking stuff apart so it was relatively easy..

i just found the dave moss video you spoke of, you can purchase it for 5 bucks right off his site

2009-Current Yamaha YZF-R1 Fork Service

Learn to take your forks apart in this suspension service video for a 2009-Current Yamaha YZF-R1. Professional suspension tuner Dave Moss provides detailed step-by-step instructions of taking the fork apart, cleaning the components, replacing the oils seal, polishing the fork tube and reassembling the fork and establishing the correct oil height. The 664mb download is 25 minutes.

if you're doing the valves i'm assuming you're getting the ohlins FPK 108 fork piston kit... you will actually find pretty damn
good instructions on the install manual for these so its good to check it out even if you're getting something else... i have attached it
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Attached Files
File Type: pdf MI_FPK108.pdf (1.90 MB, 12 views)

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Last edited by bacchus40; 12-12-2012 at 04:38 PM.
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