'91 Honda CBR600F PC25 - Part 2 - Service for front shock absorbers

Here's a short story about how I rebuild my CBR600F front shock absorbers. Other side of them was leaking quite a lot so I decided to rebuild them with Pyramid Parts Front Suspension Overhaul Kit made for Honda CBR600 F2 F3 1991-1998 (IB11 & OB22). You can find part diagrams for '91 CBR600F for example from CMS. Here's part diagram for front fork which helped me for this small project. First step of it was to lift up the front end of the bike and to get the front shocks out.

Hoisting up front end of my bike
with Chain Block & Tackle

I tide a cargo/load strap around front end frame beams and secured it with a knot which I then attached to the chain block and tackle. Piece of wooden block helped keeping the strap away from cables running aside frame beams.

Closer look of cargo strap tide around
upper frame beams

Front brake calipers had be removed
to get front wheel out

Front fender is secured with two bolts on each side of the fork
and other one also holds brake line hose

Both of those bolts can be loosened with front wheel still in place.

After getting the front wheel off I was able to remove forks out of yokes. I started by removing securing circlips (5) from top of each fork and removing clip-ons. Each fork is secured to top and bottom yoke with two bolts (21) and (11). After getting them out forks just slide out.

Front forks are off!

First step of rebuilding them was to drain out
the old fork oil. Oil drain screw is
located below brake caliper mounts.

I used a small screw driver to remove
old dust seals...

...and circlips which secure oil seal below it.

Then I secured front shock absorber to a vise...

...and used an impact driver to get the lower tube bolt out.

After removing circlip and lower bolt tube can be separated
from stanchion just by pulling them apart.

Condition of old slide and guide bushes.

I disassembled the rest of the forks after removing the lower tube and cleaned them with brake cleaner. Springs inside the stanchion are loaded so be careful when you take out the top cap. I applied bit of pressure to them while unscrewing to stop them from flying off. They are made out of aluminum so those fine threads which keep them in place can be easily damaged if you're not careful with them. I decided to reuse old O-rings in them together with copper washers in lower tube bolts.

I used brake cleaner to clean parts of shocks.

Pyramid Parts Front Suspension Overhaul Kit for
Honda CBR600 F2 F3 1991-1998 (IB11 & OB22)

Fork oil seals

Slider and guide bushes

Stanchions rebuild with new parts.

CRC Soft Lock threadlocker...

...for securing lower tube bolts.

Since I don't own any special tools for rebuilding forks I made a washer looking thing out of nylon sheet which I placed on top of oil seal when I hammered them in with a small punch. It kept them undamaged while hammering.

Nylon washer to keep oil seal undamaged
while hammering it in with a small punch.

Circlip back on to secure oil seal.

I used a rubber mallet to gently
hammer in dust seals.

Rebuild shocks ready to be put back to the bike.

Remember to add threadlocker also to brake
caliper bolts. They can easily get loose without it.

I bought 2 litres of Belray 10W fork oil...

...and measured roughly 0,508 litres for each shock 
which was recommended by service manual.

Small funnel helped with refilling shocks with fork oil

Ready for a test drive 😎