fork seals

[ROD]

So Ive now got all my new seals and bushes for the forks(.GSXR 750 USD's )
   After viewing a few vids on u tube Im still none the wiser as to how to put the oil in each fork! The forks are cartridge type,so what about getting the air out of the oil after Ive put the correct amount in?(Ive seen the damper rod pumped in and out to expel air,but my damper rod will be inside the cartridge? . Im going to remove the bottom bolt and pull out the whole cartridge,do the seals and replace the bushes. Do I slide the cartridge back in then put the oil in? Been waiting a long time for the bits now Im stuck again! HELP
 
 More Q's....I know the total amount of oil needed in each leg,butIf I have to strip down the cartridge to fill it with oil ,as well as fill the fork outer tube after I fit the cartridge,how do I know what amount of oil to put in the cartridge vs the outer tube?

[one arm bandit]

do you not just pour in in the top then put the cartridges in, they have little holes in the dampers that sucks the oil in to the cartridge?? ile have a research in a bit if knowone comes up with the answer, i havnt done usd's yet but id have presumed i pour the oil in the fork leg then put the cartridge in, is there a hole at the bottom so you could turn them usd to bleed??

[ROD]

The cartridge must be in to top up the oil,as theres a bolt at the base.

[one arm bandit]

ive done some detective work rod and came up with put the drain plug in the bottom with a new crush washer, then slide in the cartridge remove the top cap and fill with oil to bleed work the fork leg untill theres no bubble coming to the surface then install the top cap and tighten fully. most write ups say the same and insist that all usd cartridge forks will be done this same way. hope that helps in some way dont forget to count how many clicks when you remove the top nut

[ROD]

still confused mate! Surely if Ive removed the cartridge,then the top nut will be off,ie undone from the top of the leg tube? do i replace the cartridge,then just pour the oil down the side of it? or do i have to remove the top nut from the actual cartridge

[one arm bandit]

is there a 17mm nut under the top nut by under i mean on the underside of the top cap?? the cap should come off so yor left with the cartridge and the preload adjusters  and no cap?

[ROD]

Yes there is,but Im still confused. Seems to me theres 2 ways to remove the cartridge.....
  One is to remove the allen bolt at the base,then unscrew the top cap and slide the whole lot out.
  OR just remove the top cap leaving the cartridge connected at the bottom allen bolt and slide the outer casing over that.
   I cant see why the second method  would be used?? or is that to allow oil to get down inside the cartridge when filling? or maybe to get round having to struggle to remove the bottom allen bolt(mine came out easy)
 P*****d off now,as summat so simple is causing me grief!
 

[ROD]

update......
  So heres the low down from a Suzuki dealer I rang 10 mins ago...........his advice,not mine!
  Taking the top apart to slide the fork tube off is a way of getting round removing the bottom nut if it wont come off.
  Be careful when adding oil ,as you probably wont get all the oil out of the cartridge,therefore allow about say,20cc less, to account for this.Correct way is to use a tool the dealers have to account for air space and cartridge space,and taking a measurement from the top of the tube to the surface of the oil,but doing it DIY is ok
  You could pump the forks gently to expell air before putting nut on and sealing up,but after the first few bumps/braking they will bleed the air out of the cartridge anyway.
  If the test ride shows that the forks are too 'hard' this will be due to too much fluid.
 
 
 S-o-o-o............,Im calmer now ,and will go top up the fluid using a measuring tool I borrowed from work.It'll probably take me a while as my eye is still playing up !
 
  Thanks to Luke for his advice.
           Rod
 
 

[one arm bandit]

85mm air gap at the top is what i read, thats how they do it incase some fluid is left in the cartridge