Fork seal leaks - KawiForums - Kawasaki Motorcycle Forums
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post #1 of 5 (permalink) Old 12-25-2012, 01:56 AM Thread Starter
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Exclamation Fork seal leaks

Hello, Being new to this site i am posting for the first time as required...I bought an ageing 1999 zx9r that belonged to a dear friend that has passed away...I have restored the bike by general engine maint. and o-ring chain and sprocket set, and some new tires...The body was in bad shape, so its been replaced and painted....I have been riding for 27yrs total....Riding this bike for the last 2 yrs...
Now this new problem has popped up !...The right front fork is leaking oil..It seems to be comming from the dust cover area....Can someone shed some light on this, and or tell me what to expect when going to repair this ?..I have a Factory service manual
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post #2 of 5 (permalink) Old 12-25-2012, 02:51 AM
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The fork needs to be disassembled and the seal needs to be replaced. I don't recommend doing it yourself unless you know what you are doing. Cost me 300 to get mine done even after I removed the forks and brought them in.

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post #3 of 5 (permalink) Old 12-25-2012, 12:47 PM
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Try this first- you can make one of these cleaning tools with an old 35mm film negative or a thick paper business card cut to the same shape, but it is less likely to work for seals 13 years old that are more likely to be cut or cracked:

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post #4 of 5 (permalink) Old 12-25-2012, 12:56 PM
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Congratulations, Jeff!! You posted up the very first link that is actually useful, AND I was going to suggest the very same thing.

OP I actually went cheap and cut a tool out of a Chinese food container in the shape of the Seal Pro tool. Yeah they're $5 at Cycle Gear, but I was lazy and didn't feel like making the trip. Besides, the tool was essentially free to make since I took the lid froma dude at work after he finished his lunch.

I used my tool to clean the seal out on my old R6 and it worked just as shown. I had to take the bike for a ride to get the seal to reseat though. So get or make a tool, clean out the seal, then go for a ride (take a rag with you). Stop periodically to wipe the fork clean again, then continue on. If the seal reseats and there's no signs of anymore leaking, you'll need to flush and replace the fluid because I guarantee the fluid is dirty.

On the other hand my VTX had a leak and my tool failed to do the trick, so really it's a hit or miss thing. The seal on my VTX was stupid easy to replace though, so I went ahead and knocked it out (and I have experience doing this crap). Good luck.

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post #5 of 5 (permalink) Old 12-25-2012, 10:31 PM
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I just recently replaced the fork seals on my 2001 zx6r i did it myself its not to hard to do i think there is a thread on here about how to change them but It helps if you have some sort of mechanical know how

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