Changing an fork oil seal on a ZXR400L

Bod · Traffic Copper Joined: 18 Mar 2004 Karma :

Hi all, I've just bought this bike on Monday, and have realised I need to change the fork oil seal. Is this easy to do ?
Cheers
Bod

Ste · Not Work Safe Joined: 01 Sep 2002 Karma :

No is the short answer.

How mechanical minded/ talented are you? Fork seals are a bitch to do on a bad day, and being USD forks they're even more hassle and need special tools and stuff.

Shaun · Likes 'em bent Joined: 17 May 2003 Karma :

I have a ZXR400 and attempted to do the fork seals my self, I did get scared of by how complex the forks looked when I opened them so I paid £25 and had a shop do them, much easier. Very Happy

Robby · Dirty Old Man Joined: 16 May 2002 Karma :

Fork seals are easy, if you have an ounce of mechanical competency, but you will need a special tool to undo the bottom bolt.

Then its really just a case of pulling the forks apart, changing the seal, and putting it all back together again with some fresh oil.

Use the haynes manual, and don't be scared to ask your local kawasaki dealer what the tool costs. The suzuki one is just a T-bar and 3/8ths special socket. The t bar cost 15 quid and the socket cost a fiver.

Bod · Traffic Copper Joined: 18 Mar 2004 Karma :

I have never worked on a bike before, but I am quite skilled working on a car. I've managed to get the service manual off the Internet and looked at the procedure. It looks a mammoth task to be honest, and would not like to mess it up. I have rang garages and they are saying they would charge £80 to do it. Is this steep or what? I live in the Rochdale/Oldham area if anyone know's any where cheaper. Just don't know what to do?
Cheers
Bod

Ste · Not Work Safe Joined: 01 Sep 2002 Karma :

It's about two hours labour for a garage. So you just need to shop around really. Smile

McJamweasel · BCF Junkie Joined: 22 Mar 2002 Karma :

if you are comfortable with taking the forks off the bike yourself it will lower the cost somewhat. If you are going to do that try calling smaller engineering shops, they might well be able to do it and cheaper than a bike shop.
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Bod · Traffic Copper Joined: 18 Mar 2004 Karma :

I've decided I will attempt to do them myself. What's the worse that can happen, I balls it up take it to kwak and get it done? Ill buy all the specialist tools too, start building up my bike tools Confused

Kickstart · The Oracle Joined: 04 Feb 2002 Karma :

Hi

From memory when I looked at the instructions that Shaun had for the ZXR forks it did look like quite a complex job (mainly because they are upside down forks).

I would second what Col says, and think about dropping the forks out yourself and then taking them in somewhere. Supporting the bike and taking the forks out is fairly simple, just a bit time consuming so it is easy for you to do while avoiding a pointless labour bill.

All the best

Keith
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Bod · Traffic Copper Joined: 18 Mar 2004 Karma :

Thanks for that. Any ideas how i can support the bike while getting it off? It all depends on how much the special parts cost too. Decisions, decisions Rolling Eyes

Bod

Robby · Dirty Old Man Joined: 16 May 2002 Karma :

normal way for me on a bike with only a side stand is to get some bricks inder the swingarm on the opposite side to the stand, get a car jack under the engine as far foward as possible, and very carefully jack it all up.

Scouse · World Chat Champion Joined: 12 Feb 2004 Karma :

When I took Shauns forks off I was lucky enough to of picked up a front paddock stand with him the day before which made things a lot easier. (only cost him £70)

Bod · Traffic Copper Joined: 18 Mar 2004 Karma :

I was looking at the job today. It doesnt seem that difficult removing the fork, so I will remove them both myself and take them in probably or have a look at it myself?

Bod · Traffic Copper Joined: 18 Mar 2004 Karma :

Right, sorry people for asking all these questions, but...........is it possible to remove one of the forks, while leaving the wheel on, and the other fork on the bike?
Cheers
Bod

Ste · Not Work Safe Joined: 01 Sep 2002 Karma :

Bod · Traffic Copper Joined: 18 Mar 2004 Karma :

Right ok. I was thinking then, buying a paddock stand to support the rear then letting the bike rest on the floor. Would this work?
Cheers
Bod

Ste · Not Work Safe Joined: 01 Sep 2002 Karma :

Nope. You'll need a rear paddock stand, and a front paddock stand which supports the bike by the yokes.

Bod · Traffic Copper Joined: 18 Mar 2004 Karma :

rite so if i get both i should be ok then?

Ste · Not Work Safe Joined: 01 Sep 2002 Karma :

Bod · Traffic Copper Joined: 18 Mar 2004 Karma :

Ok, I've been trying to think of a way to support the front end of the bike while I take the forks off. Bare in mind, I'm doing this in a kitchen so cant do anything major? Any ideas?
Cheers
Bod

Robby · Dirty Old Man Joined: 16 May 2002 Karma :

car jack (s), bricks, railway sleeper. That kind of thing does the job nicely.

Bod · Traffic Copper Joined: 18 Mar 2004 Karma :

Ok nice one cheers for that. Is it worth taking off the fairings to do the job too?

cerebus · L Plate Warrior Joined: 03 Oct 2019 Karma :

i would just rather buy used forks and switch them out

Nobby the Bastard · Harley Gaydar Joined: 16 Aug 2013 Karma :

Ste · Not Work Safe Joined: 01 Sep 2002 Karma :

Sounds expensive to change the forks rather than the seals. Laughing