Fork allen bolts not finding piston rod??

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Dextermckay
Posts: 5
Joined: Wed Mar 11, 2015 9:12 pm
My Bike: ZXR400 L1

Fork allen bolts not finding piston rod??

Post by Dextermckay »

Hi guys,
I've spent today changing the dust and oil seals on my forks (L1). I put it all back in the correct order but the allen bolts at the base of the fork will not find the piston rod thread, I've tried compressing the forks while tightening the bolt to no avail. I am yet to put the oil in, although I don't see how this could affect it all fitting in together.

Does anybody have any ideas as to what I'm doing wrong, or how to sort it out?

Any help is much appreciated, thanks
Dextermckay
Posts: 5
Joined: Wed Mar 11, 2015 9:12 pm
My Bike: ZXR400 L1

Re: Fork allen bolts not finding piston rod??

Post by Dextermckay »

Got this sorted now - the answer was a hydraulic press to nearly (30mm away from) bottom the forks out
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ricardof1rst3
Posts: 4
Joined: Tue Aug 27, 2013 5:48 pm
My Bike: Kawasaki ZXR400

Re: Fork allen bolts not finding piston rod??

Post by ricardof1rst3 »

I found the forks go coil bound with 17mm of travel left. I used a threaded M8 rod to "grab" the end of the damper rod and pull it as far as it would go as I couldn't get the threads "in range" of the allen bolt. I have posted a long winded description here: http://www.zxrworld.co.uk/zxr400oc/view ... 22&t=17860.
1983 DT100 | 1985 TS125X | 1986 GPZ600R | 1987 GPX750R
1988 FZR1000 | 1989 FZR1000 EXUP
1991 ZXR400 | 1993 CBR900RR
1996 ZXR400 | 2000 CBR600 | 2004 CBR900RR
2013 ZXR400
2021 K1600GT SE (I know, old git alert - still got the ZXR though)
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