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Discussion Starter #1
I need some advice on how to remove the fork cap from the inner fork assembly. This is for an '05 ZX-10R.

I've followed directions from Garthman (http://www.garthmanracing.com/forkseal.htm) and the instructions from Traxxion Dynamics. I'm using the Traxxion Dynamics spring compressor tool to try to get the job done. Unfortunately, I cannot compress the spring down far enough to place the holding tool; the outer tube assembly is too tall. I've check with the Kawasaki manual, and they suggest using a spring compressor. I do not have access to a spring compressor for motorcycle forks, only one for automotive use.

Does anyone have any experience with this problem? Am I doing something incorrect?
 

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Servo's Eliminatus ;)
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When I did the fork seals on my 05, I tried the same as you following Garthmans

how to. What I ended up doing was Remove the Banjo bolt from the bottom

and take it apart. ( Remember or take a pic of which way the seal is installed

before you remove it to have a reference for when you install the new one.)


You really don't want to put them in upside down. So make absolutely sure.

When installing the fork tubes back into the triple tree, install front wheel but

leave it a little loose to be able to adjust your forks.

Read this thread for making sure your forks are straight...

http://zx-10r.net/forum/showthread.php?t=78039


Definitely make sure you torque everything properly or it will cause problems.

Hope this helps ya bro.
 

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Discussion Starter #3
I was thinking of removing the Allen bolt from the bottom. I read of someone using an impact Allen head to remove it but I don't know of a place that sells an impact Allen head. That may be my second to last resort.
 

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Servo's Eliminatus ;)
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I was thinking of removing the Allen bolt from the bottom. I read of someone using an impact Allen head to remove it but I don't know of a place that sells an impact Allen head. That may be my second to last resort.


Yeah, that's the banjo bolt.
 
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