Kawasaki ZX-10R Forum banner
1 - 14 of 14 Posts

·
Registered
Joined
·
7 Posts
Discussion Starter · #1 ·
I noticed a small amount of film on my right fork today. I slid a thin piece of platic under the dust seal to make sure it wasn't just dirt. Now the leak is massive.

Did I make it worse?

I am fairly mechanically inclined and want to change the seal myself. I have seen the write ups on it.

What special tools do I absolutely need, and where can I get them for a reasonable price?

Thanks.
 

·
Blitzkrieg
Joined
·
4,473 Posts
just had mine doen. 4k miles, right one was leaking. took them both and had them replaced, warranty. you ever done forks before? if not i would proly not do it yourself. its not super difficult. but if you can have them done under warranty then i would go that route.
 

·
Registered
Joined
·
7 Posts
Discussion Starter · #3 ·
No warranty. If I had the special tools, or even knew which ones I needed exactly, I would tear it apart tonight.

Im guessing the main issue is compressing the spring to get the top plug off and on. I am still a little uncertain about oil level.
 

·
Blitzkrieg
Joined
·
4,473 Posts
you can get the fluid guage from like "motion pro" or something, yeah the spring is not too bad but without the right tools you could do more damage than you want. just about as aggravating taking the b!tches off the bike, and putting them back on, than doing the fork seals. good luck with them though.
 

·
Blitzkrieg
Joined
·
4,473 Posts

·
Registered
Joined
·
220 Posts
if you have a welder and some good air tools you can make the spring compression tool for under 20 bucks yourself.

Other then that, you only really need a good (clean) metric tap measure, something to suck the fluid out if you put to much in, (or a the motion pro deal [Much nicer]!), and a good impact with a #8 long (at lest 2½" long) allen head socket.
I have also used PVC tubes (with good results)to install new seals.

the tool I made Just tonight with about an hours worth of labor.
I should have made it just a bit wider on all 4 sides but it still work nice.
 

Attachments

·
Registered
Joined
·
1,153 Posts
i didnt even need to compress the spring to replace my seal. i just kept the inside piece of the fork as one unit and took apart the outside of the forks to replace the seal. i ended up ordering the parts but not using them :dontknow:
 

·
Registered
Joined
·
1,688 Posts
Normally on dirtbikes you can use a thin
piece of plastic to clean out dirt from leaking
fork seals. (probably not the case here)

Are you on a 3rd gen 10? If so, I wouldn't
doubt that your forks are pinched together
possibly causing premature wear on seals.

I made some custom spacers for mine.
 

·
Registered
Joined
·
1,153 Posts
download the service manual (not the same thing as owners manual) online and there will be a section on how to change fork seals in the suspension section. it will tell you all the tools you will need to do the job. however, as it turned out for me, i did not need all those the tools they suggested in the service manual and i was able to change the forks without using them. in the service manual, they took apart the entire fork including inside unit containing the spring (which the spring compressor is supposed to be used for), but considering the fork seals where between the outside fork cylinder and the inside fork cylinder i just took apart these two things and changed the forks seals without using the spring compressor.
 

·
Registered
Joined
·
220 Posts
download the service manual (not the same thing as owners manual) online and there will be a section on how to change fork seals in the suspension section. it will tell you all the tools you will need to do the job. however, as it turned out for me, i did not need all those the tools they suggested in the service manual and i was able to change the forks without using them. in the service manual, they took apart the entire fork including inside unit containing the spring (which the spring compressor is supposed to be used for), but considering the fork seals where between the outside fork cylinder and the inside fork cylinder i just took apart these two things and changed the forks seals without using the spring compressor.
How did you know how much oil was still in your fork when you did it that way? Is there any thing in the service manual that says how many ounces of oil to put in?
the only other question I have is, if your going to change the seal why not change the oil at the same time?
 

·
Registered
Joined
·
7 Posts
Discussion Starter · #12 ·
I was thinking I didn't have to take the internals apart like the service manual says. It would be nice to clean everything while you had it apart.

What is necessary to remove the inner tube from the outer tube and get to the seals and dust seals? Just removing the fork and taking off the top cap? How does the damping rod attach to the bottom of the fork?

I would like to do all this and change the oil without needing a tool kit and saving 100 bucks.

BTW this is on an 04 10-r.
 

·
Registered
Joined
·
220 Posts
I was thinking I didn't have to take the internals apart like the service manual says. It would be nice to clean everything while you had it apart.

What is necessary to remove the inner tube from the outer tube and get to the seals and dust seals? Just removing the fork and taking off the top cap? How does the damping rod attach to the bottom of the fork?

I would like to do all this and change the oil without needing a tool kit and saving 100 bucks.

BTW this is on an 04 10-r.

I suppose you would only need an 8MM alien head socket and a good impact gun to get the bolt out.

I'd suggest that you should redo your forks completely, but I guess if you want, you could do it this way.

1 remove the front wheel
2 remove the fork
3 flip fork upside down
4 you'll be able to see a 8mm socket head bolt in the bottom of the fork, Hold fork firmly and remove that bolt with an impact.
Now, the bottom leg of the fork will slid out.

when you put it back together, hand turn/start the 8mm socket head bolt, And us a good torque wrench to tighten that same 8mm socket head bolt.
 

·
Registered
Joined
·
101 Posts
Just noticed today the left fork on my '06 is leaking, with low miles too.. anyone have pics on how they took the fork apart without messing with the spring?
 
1 - 14 of 14 Posts
Top