Front FORK rebuild - or replace??

[swiftb]

Since buying my 2000 ZX6R from a guy a lot taller and heavier than me Ive had an ongoing battle trying to get suspension settings right.
After much tinkering I now have the rear shock exactly how I want it. Im still not happy with the front but due to the L/H compression adjuster being seized I cant improve it any further. Im getting a stiff ride from the front and I think its compressing and rebounding too quickly causing a sort of 'jibber jabba' teeth chattering affect over less than smooth surfaces. Im also getting the front trying to run wide when cornering hard.
I dont know if the fork springs or oil have been changed to suit the previous owner so not sure whats in there.
Question is whats my best and cheapest option? I initially thought of buying some used forks so I can simply do a straight swap. Only problem being is theres no guarantee springs and oil havent been tinkered with and as with all used stuff they may be no better than what I have.
Im thinking of changing to some progressive springs and new oil to match my weight and having the compression adjuster sorted at the same time. I can remove the forks myself - does anyone know any specialists where I can send my forks for a refurb and roughly how much it would cost?
Or anyone know of any tricks to sort this compression screw in the meantime? Ive tried soaking in wd, tried various methods including a firm bat or two with an impact driver. Dont want to heat it incase it fuks any internal seals/damages paint etc

PS. forks have 30,000miles under their belt

cheers

[ToGGoT]

How technical are you?

I rebuilt and refurbed the forks on my brothers R100GS, and will do the same on my Kawasaki if i have it long enough.

Its a very messy job, but not difficult, especially if you have a service manual to check yourself with.

ToGGoT
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2005 BMW R1150R

[swiftb]

time served car mechanic but never really tinkered with bikes until I got this one. Im comfortable with stripping it etc - its more getting chance to do it and having the right tools as im not sure if some kind of spring compression tool is required?? Plus its getting hold of the parts, i know internal rebuild parts can be easily bought but will i be able to buy a new compression adjuster screw for example??

[ms51ves3]

You don't need a tool to compress the spring. Replacing the spring and oil is a very easy job.

Undo the cap slightly while the fork is still in the yokes, remove the fork, undo the cap being careful as it is under compression from the spring, remove the spring and drain the oil. Carefully pump the fork up and down to get all the oil out and then pop in your new bits. Repeat for the other fork.

[ToGGoT]

And, when you've added in the swearing because you've put that spanner down somewhere, the repeated stops for cups of tea, and getting oil on the phone because you forget yourself when it rings, its really is that easy...

ToGGoT
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2005 BMW R1150R

[swiftb]

How much 'compression' is it under? im used to macpherson strut springs etc being under a lot of compression. (although ive removed springs in the past without compressing them - mucho fun )
My main concern is this compression adjuster at the bottom of the fork. If I fuk it can it be replaced?? Whats behind the screw?
Also Ive read if changing to progressive springs the spacer needs to be modified/shortened??
Ive never had any quarms about modding things for cars etc in the past but tend to think things through a bit more when tiinkering with a bike, as a simple mistake is more likely to end in tears/disater/death!

[Fortuna]

Don't look over it
I did mine by suspending the bike by the handlebars then lowering it once the tops were removed.

[ms51ves3]

I put the paper bin on its side and then aimed it into that. I also put a rag over the cap which in the end was enough to stop it once it popped off.