Gumby fork seals pls help

[IsleofNinja]

I know they have been done to death ! I have mine off and kinda apart and appear to be suffering from oldtimers disease or something !? Any one got a link or pdf manual re 06 ZX10r fork seal replacement ??
I just can't remember how these come apart !?

hope everyone had a great Xmas

[IsleofNinja]

Sorted !
Kawasaki decided to use a lot more loctite than usual on the damper rod bolt (8mm allen key in bottom of fork leg) . Another special service tool fabricated to spread the body from the tube plus 8mm extended allen key socket for rattle gun and we are in business Been a while since I've been on the gumby ! Hope it didn't mind me riding the Spooky and Hardly Ferguson all this time !

[Gosling1]

Hi Matt - how ya been and Merry Xmas as well

[IsleofNinja]

Hi Gos . Has been a while .
Next Question gurus . Am using Bellray 10W . coz that's what I have plenty of pretty sure with the forks fully compressed the oil level should be about 120mm from the top ??
Can anyone clarify / pics ?


Macca .... Dave .... anyone ?

[oldmanmike]

I have the full service manual for 06/07 ZX10r.
Its 14.5mb, and I only have a shitty 3G dongle which most of the time is slower than dial-up...fuggin Optus thieves, but that's another saga.
Its a pdf so I can easily put it in a CD. PM me if you want it.

[IsleofNinja]

Awesome thanks for that Mike

The bit that has me scratching my head is how do you check the oil level ? I know is says have the forks compressed and the spring out .. Not sure how the hell you do this whilst keeping the oil in !?

[Gosling1]

wih the springs out - the forks should just compress easily - a wooden dowel makes a good dipstick to check the oil level

[Wattie]

If oil is coming out with the forks fully compressed, then there is too much oil in there. I think...

[IsleofNinja]

Ok
Forks have been re assembled and back in the bike with as accurately as possible measured amounts of 540 ml each fork . (assuming that I bled the old oil out of eack fork's damper valves evenly.).(Did not want to put the full 567mm amount in as the forks were not completely stripped and cleaned only required fork oil and wiper seals - have only done 22K and old oil was spotless .....Damn ! did I just admit that on KSRC ?? ) yes 540mm is a stab in the dark - hence why I need to know oil level setting/checking procedure.

Firstly I remove the forks again
To check / verify that i have the correct oil level in each fork now . I would remove the top cap (24mm triple clamp end) , then extend forks and remove the 8mm socket head cap bolt from the bottom (caliper end).
I would then remove the damper assemblies by extracting from the top via the top cap / spring pre load adjuster ass'y
Then the forks should be fully compressed (piss easy without springs)
Then we check oil level ?

Bear with me peeps .....

What I'm asking is : do we lose any oil when the bottom bolt (8mm socket head) is removed ? I would assume as soon as this is loosened the forks drain themselves ?

NB: I'm prob being a bit anal coz I know Macca had a lot of dramas with his trackie a few years ago all relating to oil levels . You guys prob do this kinda job all the time pretty much in your sleep! I don't anymore. Kinda hard as i'm normally the 'go to guy' This time I just don't know exactly
Thanks for your input to date - appreciated

**Feel free to edit / correct this post as necessary**