Fork modifications - Gen 1 ZX10R - Kawasaki ZX-10R.net
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post #1 of 49 Old 09-24-2018, 01:03 PM Thread Starter
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Fork modifications - Gen 1 ZX10R

Hi,

just took the 04 forks apart and can't locate anything resembling a shim stack/valve assembly,

it's a damper rod cartridge Kayaba, but it's difficult to find any good info out there about its

tunability. (why is that so?)

Sag is good, so the spring stays but the front end is really vague and lacking in feel not giving

any confidence entering corners.

I'm new to suspension tuning but wanted to start working and learning on my track bike.

Racetech sell a gold valve kit (compression) and that's probably the way to go, but still if I could

improve the stock stuff and save a bit... mhmmhmh...

what do the pros say?

Cheers
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post #2 of 49 Old 09-24-2018, 02:53 PM
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The pros say OEM fork pistons suck and aren't worth the time or effort to mess with. That is why 25 & 30 mm cartridges exist.

My memory ain't what it used to be, but I kinda remember those early Kawi rods were swedged making it difficult at best to get to the pistons.
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post #3 of 49 Old 09-24-2018, 07:05 PM Thread Starter
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Right, thanks

So to get to the valves, can I just use a spanner on that cap? is it threaded?
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post #4 of 49 Old 09-25-2018, 12:09 AM
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I have Racetech valves in a couple of my bikes forks. They work great. I have owned Ohlins carts too, they also work great. Call Racetech. They are very helpful. Yes, I believe that part is threaded but you will find out soon enough once you try to turn it with a wrench. Use some penetrating oil on it. You can make a rod holding tool with a block of wood and a hole saw so you don't crease the tube.
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post #5 of 49 Old 09-25-2018, 06:24 AM Thread Starter
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Thanks for chiming in,

How is the cylinder supposed to come out? Can't see any circlips...

Not very intuitive design and then the fear of damaging something.

all new to me!

Some more photos for documentation purposes.
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post #6 of 49 Old 09-25-2018, 11:13 AM Thread Starter
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Ok,

compression valve removed, somehow the nut on the other end came loose and left the valve stuck in the tube.

It was just the rubber oring keeping it in place.

What do I do with it now?? :D scrap?
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post #7 of 49 Old 09-25-2018, 11:46 AM
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You should be able to gently pry o-ring with flathead while being careful not to scratch/damage fork tube.
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post #8 of 49 Old 09-25-2018, 12:12 PM
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Do yourself a favor and get a book like Race Techs Motorcycle Suspension Bible. You're gonna go down a dangerous path and possibly get yourself hurt if you get something wrong. RTs book will go through theory and explanations and how to fully disassemble and assemble your forks.

As to piston kits the following will work.

Race Tech
Ohlins
K-tech
Bitubo
Penske


Any 20mm piston will fit.
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post #9 of 49 Old 09-25-2018, 11:54 PM
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Quote:
Originally Posted by evallarta1 View Post
Do yourself a favor and get a book like Race Techs Motorcycle Suspension Bible. You're gonna go down a dangerous path and possibly get yourself hurt if you get something wrong. RTs book will go through theory and explanations and how to fully disassemble and assemble your forks.

As to piston kits the following will work.

Race Tech
Ohlins
K-tech
Bitubo
Penske


Any 20mm piston will fit.
Good advice, as there are nuts that need lock-tite etc. A Racetech goldvalve kit will give you the info and the parts necessary. Valving options come from the Racetech website.
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post #10 of 49 Old 09-25-2018, 11:56 PM
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That is your piston valve stuck down there inside the tube. It should have pulled out all together.
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