www.zxrworld.co.uk

Hi all,
I'm new to the forum, and hope I can get some advice to get my bike on the road fast.

I've had my 1991 400L for about 5 yrs, it lives in my lounge nestling in the bay window, apart from riding it home it has only been started half a dozen times.

The only thing I know needs doing is the fork seals.

Having been quoted £180-£200 I think I'll do them myself.

I am a competant home mechanic, and have a workshop manual, but feel experience of these things at home are often worlds away from what you read in the manuals.
So I would be grateful if someone could point me to a simplified fork seal replacement guide, and any tips on what is necessary for me carry out prior to use, and what could be carried out after putting the bike back on the road.

The bike is in great condition, and apart from a 25mm crack in the fairing near the bars and a few scratches, its almost immacculate.

Its fitted with an Ohlins rear shock, stainless exhaust, some kind of Dynojet modification, and low profile tyres, apart from which, I believe it is standard.
I have fitted a new battery.
It starts on the button, and after a few s (bit like me!) runs lovely.

Any advice will be much appreciated,

Al.

Hello Al, theres a fork rebuild on the main site

http://www.zxrworld.co.uk/zxr400/forks.html

ive not read it properly but i think its the closest weve got to changing the seals!

I replaced my fork seals and oil a week ago, cost me £70 in all, 10 for the seals, 10 for the oil, and 50 for the labour-Got a mechanic mate up the road to do it, probably could have done it, but wanted it done fast while i was at school. Check the manuals on the main site, think the 'suspension' one should have the breakdown of all the components in the forks, the only real problem you might have is raising the front end to get form off etc, the mechanic who i got to do it, used a jack to raise the front of the frame and then wedge the underneath of the engine/pipes. There are a number of ways you could do it, have heard of people using pulley lifts from above onto the frame. I'll link the ebay company i bought my seals off, if your seals need replacing then chances are you will have an imbalance of oil in the forks and needs replacing i would say, sure some people just top up, but oil is cheap and tbh i dont think worth the risk of imbalance. But definetly do not pay 180-200, never ever heard of a quote that high, most garages quoted me around 80 without parts.
http://stores.ebay.co.uk/PKN-Worldwide- ... cle-Spares
Good luck, get back to us on your decisions.

damnit, your either too fast or im too slow at typing Rob

as said all the manuals & microfiches are on site, RobB has posted the link to Diesels fork rebuild.I am doing mine over the next couple of days so will stick the camera on charge, seals are £7.25 each from cradley Kawasaki.

Having looked at Diesel's fork guide and the manual, I can't believe its the same job, the manual has a wheelbarrowful of special tools etc, and at the other extreme Diesel makes it appear as easy as checking your tyre pressures!

I don't want to scare myself out of it, but I don't want my bike suspended from the garage joists for 3 months while I look for bits that flew in all directions during disassembly!

Is there someone who has done it, that can point to errors etc I may (will) make,

Thanks,

Al.

i have done the fork seals before but it was about 5 years ago, like i said i'm gonna do mine over the next day or 2, if you can bear with us i'll try and do a full write up.when you planning on doin it?

masterofinsanity wrote:i have done the fork seals before but it was about 5 years ago, like i said i'm gonna do mine over the next day or 2, if you can bear with us i'll try and do a full write up.when you planning on doin it?

Over the weekend I hope,

I've had the bike over 5 years, I've had the seals for near 5 yrs, but Its sunny!

It shows my work is planning and programming don't it!

Al.

i used the manuals last time and never had any problems.

What about the special tools,

in the first paragraph of its stated you need a spring compressor, there are 9 special tools required according to the manual, this seems well OTT, but I don't want to get half way through on Sunday afternoon and find I do need special bits.

i didn't use any special tools but it does help if you get someone to compress the spring while you undo the nut behind it.

Thats wot I wanted to hear, I'm quite handy with improvising, and if it can be done, I can probably do it,

or I'll die trying! :smt013

Are there any particular things that I should do before using the bike, I'll do an oil change, lube the chain, check nuts and bolts, but is there any not so obvious thats amust,

thanks,

Al.

oil is a must, will need fresh petrol as well. Id check my wheel bearings to as sitting in one place for a long time can crush them. Tyres for sighns of roting, all electrics are working.

Expect the carbs to be cloged up with crap as well!

Don't forget to check tyre pressures!!!

And the other fluids - coolant and brakes...

It might be worth investing in a bottle of fuel system cleaner (STP or Wynnes etc) and tip a bit of that in the first few tanks of petrol as well.