Fork Spring removal? - Kawasaki ZX-10R.net
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post #1 of 12 Old 05-11-2007, 12:40 AM Thread Starter
 
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Fork Spring removal?

Ok, I just got my new fork springs in, but how the heck do I change them? I'm used to dirt bikes where you just take the cap off then use another wrench under the cap to loosen a jam nut. I pulled a fork cap off tonight, but everything looks completely different from what I'm used to. By the way it is an '06 10R

Also, I have a shock spring too. I haven't started on it yet, any tips?
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post #2 of 12 Old 05-11-2007, 02:05 AM
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Changing the front fork springs requires some kind of a special tool.

What you need to do is loosen the fork cap as you did, then you have to compress the spring with a sleeve of some kind until you can slide the plastic collar down far enough to get a open socket wrench (17mm I think) and hold the jamnut while youre loosening the fork cap.

You can either use the special tool that Kawasaki recommends in the service manual, or do it the hard way as we did. We used a ordinary sleeve that fitted onto the spring, but with clearance enough to let the inner part of the fork pass thru freely. Then we compressed the spring using just manpower, and there is an edge just below the jamnut where you can slide a locking washer or something in that locks the sleeve in place.

Good luck

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post #3 of 12 Old 06-28-2007, 11:36 PM
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DAMN THESE SPECIAL TOOLS!!!!!!!!!



I'm trying to install my new front springs and, well, yeah I need to start buying more tools because I just ain't cuttin it. :D

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post #4 of 12 Old 06-29-2007, 06:42 AM
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On a related note... has anyone developed an easier way to change just the spring with the forks in the bike without using Kawasaki's Spring Compression kit? I would just hate to pay $170ish dollars for something I may use once or twice from today until 2075, especially since I need a custom map soon! I got 72 miles on my last tank of gas before my light came on.

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post #5 of 12 Old 06-29-2007, 02:28 PM
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i tired fabbing my own tool much like the one pictured and the spring has a lot of tension on it by the time you start compressing. i got worried that it would slip off and tear the top cap off. if you find out a way let me know i have the same problem. i think there is a spring wrench that grabs the spring by the coils and you can squeeze the spring that way. i think it is more designed for the rear shock though.

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post #6 of 12 Old 06-30-2007, 12:31 AM
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I'm going to try one more trick tomorrow but if it doesn't work, I'll probably just end up getting this:

http://www.racetech.com/shopping/sho...howPage=street

I looked up the cost on the parts needed from Kawasaki and it was about $240 dollars retail. Since I don't see myself using it more than 4 times in the next few decade, I just can't see myself spending that much money on it.

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post #7 of 12 Old 06-30-2007, 04:48 PM
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damn i got 12k on the bike i may do mine too

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post #8 of 12 Old 07-01-2007, 04:41 PM
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i think someone on here said the racetech fork compressor didnt fit on the 10's forks or didnt work. do a search for spring compressors and see what ya get. i looked everywhere to find the tool or something close to do it my self without spending an arm and a leg. my local shop doesnt even have the tool so i dont know how i will change springs since mine is too heavy for my weight.

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post #9 of 12 Old 07-01-2007, 07:36 PM
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Quote:
Originally Posted by joedirt199 View Post
i think someone on here said the racetech fork compressor didnt fit on the 10's forks or didnt work. do a search for spring compressors and see what ya get. i looked everywhere to find the tool or something close to do it my self without spending an arm and a leg. my local shop doesnt even have the tool so i dont know how i will change springs since mine is too heavy for my weight.
If you REALLY need it, I can get you the Fork Spring Compressor Tool part numbers for the Kawasaki part if you want to place and order with your local Kawasaki dealer.

Or maybe you want to go Halvsies on one?

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Last edited by SalKhan; 07-01-2007 at 07:38 PM.
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post #10 of 12 Old 07-03-2007, 10:49 PM
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Yeah so I finally got the springs in and lets just say that unless you have the Kawasaki special spring compressor assembly, or equivalent, it's easily a 3 person job to install 1.00 kg spring.

My GOD what a colossal pain in the ass. It took myself (6-1, 220) my very accomplished dirtbike mechanic (5-9, 210) and another friend (6-3, 260... Asian no less... AHAH!) all of our might to compress the spring with a traditional push-down type spring compressor, and a small hook,to that the jamnut exposed enough to slip the grooved plate underneath it to tighten everything back up.

My God.

But with new springs and 5wt Maxima Fork Oil, it's MUCH MUCH better. I do need to dial it all in (which I hope I can do with the heavier oil - it was all we had on hand) but I'm already happy with the fact that I'm no longer bottoming out!

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