Gumby fork seals pls help

ZX6R, ZX10R, ZX14R, Ninja 1000 etc

Gumby fork seals pls help

Postby IsleofNinja » Fri Dec 27, 2013 8:07 pm

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 :)
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Re: Gumby fork seals pls help

Postby IsleofNinja » Sat Dec 28, 2013 3:07 pm

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 :D 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 ! :kuda:
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Re: Gumby fork seals pls help

Postby Gosling1 » Sat Dec 28, 2013 4:50 pm

Hi Matt - how ya been and Merry Xmas as well :kuda:
".....shut the gate on this one Maxie......it's the ducks guts !!............."
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Re: Gumby fork seals pls help

Postby IsleofNinja » Sat Dec 28, 2013 6:36 pm

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 ?
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97 GSF1200 project streetfighter
07 FXST

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Re: Gumby fork seals pls help

Postby oldmanmike » Sun Dec 29, 2013 5:49 am

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.
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zx10r fork specs.jpg
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Re: Gumby fork seals pls help

Postby IsleofNinja » Sun Dec 29, 2013 11:29 am

Awesome thanks for that Mike :prayer:

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 !? :?
06 ZX10r , 95 ZX9r
97 GSF1200 project streetfighter
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Re: Gumby fork seals pls help

Postby Gosling1 » Sun Dec 29, 2013 12:21 pm

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

8)
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Re: Gumby fork seals pls help

Postby Wattie » Sun Dec 29, 2013 8:57 pm

If oil is coming out with the forks fully compressed, then there is too much oil in there. I think...
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Re: Gumby fork seals pls help

Postby IsleofNinja » Sun Dec 29, 2013 10:20 pm

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 ?? :shock: ) 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 8)

**Feel free to edit / correct this post as necessary**
06 ZX10r , 95 ZX9r
97 GSF1200 project streetfighter
07 FXST

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