Kawasaki zx6r 1997 fork rebuild

[BikeNewbie]

Hi,

I need the seals changing which I know means the forks have to be taken apart, correct?

I don't have the tools for this job, so how much am I looking at for it to get done?

2 hour job?

Thanks.

[andym]

I'm sure almost everyone on here will disagree with me.... but I'll go ahead and say it anyway.

Unless you have a problem with the forks that require them to be completely stripped and rebuilt there is no need to go to all the effort of stripping them down.

I have done (to date), intruder 125, diversion 600, gpz 750, zxr 750 fork seals, and not once have I needed to strip the forks down.

Just drop the forks, remove the dust seals, use a screw driver to pop the old seals out then use them on top of the new seals to tap them into place... top up your fork oil, slap it all back together and you're good to go.... OK it's slightly more complex than that... but not much

This was the tools I used:
https://img.photobucket.com/albums/v320/andy36586/forksealtools_zps2e4d6c12.jpg

and this was after about half an hour:
https://img.photobucket.com/albums/v320/andy36586/forksremoved_zps635ade0e.jpg

[G]

If you can get them out that way, using a screw driver can have a serious risk of damaging the chrome on the fork, which it is VERY important not to damage.
If you can do it without damaging it, fair play.

However, seeing that most forks only need two tools to get the seals off (maybe three), it may not be such an issue for the OP to do.
Allen key for the bottom bolt and socket/spanner for the top.

I'd expect a mechanic should have them done in an hour or less if you take the forks in to them.

[andym]

[Vincent]

You can also screw a small self tapping screw into the seal to help lever it out.
If the forks havn't been touched for a long time, it might be worth stripping them down, cleaning out all the old crud and checking the bushes while your at it. If any grit has worked its way past the seal, it could re-appear and damage the new ones.

OP, you probably know this but to protect the new seal, don't forget to smear some fork oil on it and clean up any pits on the stantion before sliding it down the leg. Also clean out the seal recess really well and it's a good idea to cover the stantion in cling film too.

Also, don't fill the forks with new oil using the capacity recommendations - measure the level instead.
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