03 zxr6 bottom of fork leak

[pungent]

Hi, new to this forum and have just brought a 03 ZXR636 to get back into riding again.

I have noticed right at the bottom of the fork where it enter's the wheel and caliper holder there is a small amount of fork oil leaking.

I have gone through the manual and can not find an exploded view or any information on how this part of the fork comes apart or what will cause this to leak in this spot.

I have googled and searched forums but can not find any info on this particular problem.

I do all my own mechanical work my self on my own cars and bikes so the last thing I want to do is just drop it of at a work shop some where and get charged stupid amounts of $$ lol.

Any help appreciated and thanks in advance.

[Phil]

Hi, new to this forum and have just brought a 03 ZXR636 to get back into riding again.

I have noticed right at the bottom of the fork where it enter's the wheel and caliper holder there is a small amount of fork oil leaking.

I have gone through the manual and can not find an exploded view or any information on how this part of the fork comes apart or what will cause this to leak in this spot.

I have googled and searched forums but can not find any info on this particular problem.

I do all my own mechanical work my self on my own cars and bikes so the last thing I want to do is just drop it of at a work shop some where and get charged stupid amounts of $$ lol.

Any help appreciated and thanks in advance.

Sounds weird, sure its not the fork seal leaking and dripping down to the lowest point

[Glen]

Hopefully it's like Phil said. I've never heard of one leaking from the join before.

If you have to get the fork tube out of the bottom section/caliper mount it's not impossible but it's bloody hard. On the newer models they are threaded but with a locking screw which you need to drill out. The problem is that they are in so tight theres a good chance you'll destroy the inner fork tube getting it out. New ones are about $700 and come as one piece. A wrecker for a new fork might be a better option or talk to a suspension guy.

Good luck

[pungent]

Phil -- I was praying it was the fork seal and wiped clean and went for a ride pumping the front brake a number of times but sadly enough is from the join.

Glen -- looked at getting it out but decided against it after talking to a few bike shop's. New outer was quoted $720. A single fork from wrecker's here in australia was $400 upward without delivery= ouch.

I have purchased a single fork from america for $82 and $102 express priority post coming to $183 aus and is from a wreckers that guarantee it to be straight and good condition.

Just have to wait for it to turn up and will put new seals and oil into both front forks to make sure they are the same.

Thanks for the replies. Planning in the early new year to come down sydney way for a track day and some cruising so will hopefully get to meet a few new people.

Thanks again.

[zenodamper]

They can leak & have been known to weep on this model - exactly from that join - the stanchion into the axle holder. The fix is not that costly...

[pungent]

Now you tell me after I have already payed for another fork lol. If there is a way of stopping my current fork from leaking pleeeeeese tell. Pleeeeese!!!!

[zenodamper]

Strip it down, unscrew the part, put in new o-ring and use right sealant to screw back together with - the trick is having the clamping tools for taking it out with, other than that, it is easy enough... (oh & needs muscle)

[pungent]

Haha sound's easy enough for someone that has done it before.

[Phil]

Haha sound's easy enough for someone that has done it before.

And has the right tools.

Now, I'll need to keep an eye on mine, was it just the 03 Model Zeno, or both 03 and 04? I have 04 forks on the Z1000

[zenodamper]

Good question Phil, but I only know it happens is as far as it goes! Don't know if it was isolated to B1, with the B2 not afflicted - but, I would think B1/2 fork to be exact same without change and therefore it is a possibility it could happen to you... but but but, I do not think it is all doom and gloom, as I have had 2 B1's and neither bike's legs have leaked - relatively rare...

Shall we start on the the leaks-gas-from-new shock yet? As I cannot count the amount of those I have gone to remove the gas from, but actually not found any in it!

[StuMiller]

Hi, new to this forum and have just brought a 03 ZXR636 to get back into riding again.

I have noticed right at the bottom of the fork where it enter's the wheel and caliper holder there is a small amount of fork oil leaking.

I have gone through the manual and can not find an exploded view or any information on how this part of the fork comes apart or what will cause this to leak in this spot.

I have googled and searched forums but can not find any info on this particular problem.

I do all my own mechanical work my self on my own cars and bikes so the last thing I want to do is just drop it of at a work shop some where and get charged stupid amounts of $$ lol.

Any help appreciated and thanks in advance.

I had exactly the same problem with my ZX6 trackbike. It turned out to be the fork seals, so I took it in to Mornington Kawasaki and the boys rebuilt it and put in some heavy duty ZX10 springs.

Cost approx $500 or there abouts as I had brakes and a suspension set up done too.

Pretty easy for those who know how.

Cheers!