how to guide :2005-2008 zx6r fork seal replacement (with pictures)

[burnoutnut]

sorry about the error this is a 2007-2008 fork seal guide

Hi, in this thread ill show you how to repalce your old leaking forkseals with brand new ones its an easy job

Are your forks leaking like this????



Tools you will need:
Screwdrivers
spanners (10mm-17)
24mm socket
fork oil (manual says 10w) but i used 5w.
2 ratchet straps
a spring compressor (or if you dont wanna spend big money you can make one easy,see picture below) all it is , is a little box i welded up with some half inch threaded rod (tapered ends) and some nuts (cost about 10 bucks to make)


Ok lets get started

remove your front wheel, loosen all your fork bolts except the top triple tree bolt

take a rag throw it over the top of the fork then take the 24mm socket and loosen the top fork plug a couple of turns (it wont spring up killing you) then loosen the top tripple bolt and slid the fork out


once its off the bike finish unscrewing the cap

like so


drain all the old oil out (give it some pumps)


now grab your spring compressor and tighten it in the two holes on each side of the ally tube


grab your two straps and a socket extension bar and set it up like this


ratchet is down exposing the nut under the fork cap

[burnoutnut]

throw a 10mm spanner under the nut so you dont loose the rod down the tube


now grab a 17mm and a 12mm and undo the for cap


unscrew the fork cap and pull out the tension rod




now take your long threaded bolt with the zx6r engine mount nut on it and thread it on a few times




then release the ratchet straps and pump some more oild out of it


slide the spring cap out


then spring


slide the dust seal down by gentely priying it with a small flat screwdriver



then inside the tube you will see a pin, place the flat head screw driver in and lift one corner then follow it around



now its time to separate the tubes. to do this either get a mate to pull on the each end of the tubes or use the outter tube like a slide hammer and just pump it in and give a hard quick pull and it will pop free like this (have the oil drain ready)



once youve done that you'll see this (outter bushing/ washer/ fork seal/ pin/ dust seal)


grab your new fork seal and dust seal and slide back on in this order



now inorder to push your old seal back on your gonna have to cut your old fork seal in half with a grinder or hack saw like so

[burnoutnut]

Then slide the outter tube back over the inner fork leg and turn it upside so the top is on the floor (place a rag under it) and slide your outter fork bushing ,washer and fork seal into the slot


now take the two halfs of the old fork seal, turn it upside down and tap it in gently (must be evenly) once youve got it part way take a big flat end screwdriver and tap on the old fork seal



untill you can see with the circlip goes back into and push it in



then slide the dust seal back up and push it in



put the spring back in then the spring cap



grab your ratchet straps back out and set it up again to pull down the alloy spring cap so you can un thread the bolt and slide the tention rod back in and do the cap back up




now put 505ml of fork oil into the fork and screw the fork cap loosely back into the fork tube



throw it back into your triple tree and re tighten the fork cap back up to 35 newton meters of torque (or just snug tight)


and your done... if you've done it wright it you'll have no more leaks

i got quoted 250 to get his job done from a m/c shop so by doing it my self it cost me

$ 32 bucks for the fork seals
$ 28 for dust seals
$ 25 bucks for fork oil
and 10 bucks for the spring compresser
3 bucks for the long thread bolt (with the zx6r engine mount nut)

EAAASY has

[navajowalks]

05/06 and 07/08 are different forks just a heads up... 05/06 are even easier and don't have the extra bushings to replace.

[CRASHDUMMY]

the bad part is that u will probably have to replace ur seals again sooner than before cause u didn't change the inner and outer bushings cause that's what keeps the tubes in a line with no play to make ur seals stay tight. the more wheelies u drop or side drops wears on the Teflon and material of the bushings and the seals, and u damage them a little when u separate the inner and outer tubes........ just my

[vegasrider2005]

first off, 05-06 come apart different that the 07-08. second Ive done both and never needed the compression tool to just do seals and bushings

[StuntBikeJake]

That makes it so much harder than it has to be.... I haven't done half of those steps to replace seals and bushings.

[vegasrider2005]

Originally Posted by StuntBikeJake

That makes it so much harder than it has to be.... I haven't done half of those steps to replace seals and bushings.

Ditto, Allen at bottom. Cap off top then pull them apart

[StuntBikeJake]

^^^boom.

I never took the cap off until they were back on the bike and ready to be filled with fluid.

[vegasrider2005]

Originally Posted by StuntBikeJake

^^^boom.

I never took the cap off until they were back on the bike and ready to be filled with fluid.

I do so I can run a rag thru the tube to really clean out the old oil.