Fucked up! GPZ forks

Gazz · World Chat Champion Joined: 19 May 2009 Karma :

Trying to do a set of fork seals on a GPZ600R but have managed to make an arse of it and I currently have both forks in individual bits. I have damaged the new fork seals (they were very tight to fit into place) and I have also lost a washer as well. I have 3 washers, 2 of them are bent - dont know how they got like this. So I am assuming that I am missing one and dont know where they go either because I am a dick!

Just ordered some more seals from a different supplier in case they parts I ordered were the wrong size. The old seals slot into place fine. However I couldnt get the upper washer over it and the clip in place though, hence dismantling everything again in an attempt to put it all together again.

And now I cannot get the bush to go inside the fork, when it was going in before.

I have come across this website:
https://www.gpzzone.co.uk/acatalog/Front_Forks_A1_A6.html

Can someone please have a look at it and see what washers I need to buy and where do I put them?

Also, what does the air valve do - as some bikes dont seem to have this part?

Any help muchly appreciated.

Gazz · World Chat Champion Joined: 19 May 2009 Karma :

Furthmore, what does the air/oil balance thing do as well ?

All this stuff seems very technical for a 23 year old bike.

stinkwheel · Bovine Proctologist Joined: 12 Jul 2004 Karma :

Can't help with the specifics.

The air valve does pretty much fuck-all. Don't worry about it.

Some of the washers in forks are supposed to be bent.

What you need is an exploded diagram and a workshop manual. You also need a seal driver (known to the rest of the world as a length of plastic waste-pipe).

I strongly suspect you didn't have the bushing fully seated before trying to bump the seal down on to of it.

Do they have anti-dive?
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Ja7 · Crazy Courier Joined: 10 Nov 2012 Karma :

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Ja7 · Crazy Courier Joined: 10 Nov 2012 Karma :

Page 89 there's a diagram of the forks hope this helps.
https://dl.dropbox.com/s/7bkdaesfisoeopk/Kawasaki%20GPX600%20EX600%20GPZ600%20Ninja%20600%20R%20Parts%20List%20Diagram%20Manual.pdf?token_hash=AAEOC7hxNMWYB5aYtX6bvO03FA1ehiN0eSIO8OKP-LYMwQ&dl=1

Gazz · World Chat Champion Joined: 19 May 2009 Karma :

Gazz · World Chat Champion Joined: 19 May 2009 Karma :

Update. Just went home after work, went into the garage to organize all the parts so that I had 2 of every part and put them all nicely together and low and behold I have lost another fucking washer!!!
This is getting beyond a fucking joke. I want to punch myself in the face but worry about people asking; 'how did you do that?' I am fucking useless.

Anyway, could someone possibly find me the washers that I need on a site somewhere that I can by them from? I think all the other parts are there - except the new fork seals which will be coming in the next day or 2.