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Kawasaki Zephyr 550 1991 - leaking front fork

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garacs
Borekit Bruiser



Joined: 22 Jun 2024
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PostPosted: 12:43 - 24 Jun 2024    Post subject: Kawasaki Zephyr 550 1991 - leaking front fork Reply with quote

Hello everyone. In the process of preparing my Kawasaki Zephyr for inspection and new documents (it's a long story, don't ask...) I noticed that the front left fork was leaking some.drops.of oil.

It actually left a small puddle of oil overnight, so I inspected the bottom end of the fork.

The right fork bolt is tight and seals well, looks old and dirty as if it was never touched. The left one looks newer (shinier) and if I try to turn it it turns endlessly, taking with it the internals of the forks.

I bet I need to rebuild the fork, but I wanted some feedback from more experienced people.
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Working on it: Kawasaki Zephyr 550B 1991
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A100man
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Joined: 19 Aug 2013
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PostPosted: 13:11 - 24 Jun 2024    Post subject: Re: Kawasaki Zephyr 550 1991 - leaking front fork Reply with quote

garacs wrote:
Hello everyone. In the process of preparing my Kawasaki Zephyr for inspection and new documents (it's a long story, don't ask...) I noticed that the front left fork was leaking some.drops.of oil.

It actually left a small puddle of oil overnight, so I inspected the bottom end of the fork.

The right fork bolt is tight and seals well, looks old and dirty as if it was never touched. The left one looks newer (shinier) and if I try to turn it it turns endlessly, taking with it the internals of the forks.

I bet I need to rebuild the fork, but I wanted some feedback from more experienced people.


If its a puddle then it's probably leaking from that bolt at the bottom which shoule be sealed with a copper washer.

I had this recently I managed to nip it up with a 'rattle gun' impact driver. Otherwise you can undo the top of teh leg (might be held by a thread or a cap with a circlip and removed the spring, then you can put a holding tool down the fork to stop the 'internals' form turning while you do up teh bolt. Overall though you may wish to take the left leg off check if there's a washer in there and also fill with the correct amount of oil..
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Then: Fizz, RS200, KL250, XJ550, Laverda Alpina, XJ600, FZS600
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garacs
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Joined: 22 Jun 2024
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PostPosted: 13:32 - 24 Jun 2024    Post subject: Reply with quote

Yeah, a complete rebuild of the "leg" is going to be the way to go, I guess...

What I hear/feel rotatin inside the fork slider are the damper rod and all the connected components, as per the attached image. These I guess should be fixed, non-rotating components, am I right?
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Working on it: Kawasaki Zephyr 550B 1991
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A100man
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PostPosted: 14:04 - 24 Jun 2024    Post subject: Reply with quote

garacs wrote:
These I guess should be fixed, non-rotating components, am I right?

No they always rotate, so you have to hold them ..
..often there is a hexagonal head on the top of the damper rod so you can buy or build a tool to hold it.
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Now: A100, GT250A, XJ598, FZ750

Then: Fizz, RS200, KL250, XJ550, Laverda Alpina, XJ600, FZS600
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garacs
Borekit Bruiser



Joined: 22 Jun 2024
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PostPosted: 14:38 - 24 Jun 2024    Post subject: Reply with quote

A100man wrote:
garacs wrote:
These I guess should be fixed, non-rotating components, am I right?

No they always rotate, so you have to hold them ..
..often there is a hexagonal head on the top of the damper rod so you can buy or build a tool to hold it.


Will have to check that out. Thanks for your input.
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