time for fork overhaul!

[gixxerdave]

guess its been a long time coming... my 02 zx9 had one of the fork seals spring a leak last weekend.. not messy but the area in question is wet so i'd like to fix it..

anybody got a manual i could use as i plan to pull em out of the bike and do the job myself this weekend..

if any of you have it in an emailable file, pm me and i'll send my address to you..

cheers guys

[Steve_TLS]

I'm not sure of the fork differences between the 98-99 models and yours, but you can download a pdf version of it from here >> http://www.r1budha.com/servicemanuals/

For USD forks you need to make a few tools to do it. Mainly a spring compressor and damper removal tool.

[Steve_TLS]

I didn't see this link >> http://www.ksrc-au.com/phpBB2/viewtopic.php?t=980 the site has a few available too. Same years for the 9 though.

[mike-s]

i've done my forks on my old bike (abeit non USD), so if you want a hand with arsing it up on Saturday arvo, i'm more than willing to give a hand for a spell if your interested .

i have some pvc tubing that i used before that might work to help knock spacers in & out too.

The above is all pending on my getting my sorry backside out of bed at a reasonable time (midday ->1pm or so i'd guess) after a nightshift that ends at 7am!!!

[aardvark]

anybody got a manual i could use as i plan to pull em out of the bike and do the job myself this weekend..

I know this bloke who is really good at replacing fork seals in Kwakkas. He's had plenty of practice and learned from all of his mistakes.

I can put you on to him, and hopefully it wont cost you twice as much as the shop quoted!

[Neka79]

hahahahah u dont hold a grudge do u jase??

[aardvark]

Nah, I don't... I still think it's funny!

[Neka79]

haha so do i...piss funny really, now that its all sorted...

[gixxerdave]

well,

thanks guys for the info you put up on here, much appreciated..

i got my forks sorted over the weekend... and silly me, i forgot to take pics of the whole process so i could put it up in the how to section..

hmm, oh and now i know why the bike was always handling slightly different on a lot of rides.. 350ml total (from both forks) of oil was drained... and a litre of oil went in.. so essentially i was getting round on crapped out forks!

and thanks to a lot of patience and info from madkaw over the phone, i had the forks back in the bike with minimal sweat and tears

apparently there's some really bad pitting on the fork tubes... along with a *nasty* nick in the LH fork tube that caused the leak... the shop that did my seals smoothed out the nicks with some wet and dry and it was all good.. tho i suspect i might have to replace them at some stage...

now to get the sag done!

madkaw - i have something for you.

cheers

[MickLC]

Glad to hear it all went well mate, but next time remember the camera

[MadKaw]

Great news Dave, I wasn't sure if I was being much help.

Was the oil level from the top of the tube the same as the 98 model, 145mm..??

[gixxerdave]

i havent got the specs for the 02 model but im pretty sure it should be the same for the 98..

no leaks so far

[Neka79]

no leaks yet?? bring it round for jamie to fix, im sure ull have some then!!..lol