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All Things 550 » Maintenance and Repair » Suspension » Zephyr 550 front fork seals

Zephyr 550 front fork seals Options
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Jason
Posted: Monday, April 12, 2010 2:29:54 AM
Rank: n00b
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Joined: 4/12/2010
Posts: 10
Location: Dorset, UK
Hi all.

Just bought a Zephyr 550 project after a few years away from biking. I need to replace the front fork seals.

I'm pretty mechanically handy but before I start is there any trick I should be aware of? I'm trying to avoid stripping the forks down too far, so what's the minimum level of stripping required - i.e. can they be done a leg at a time without taking the forks completely off the bike?

Also, anyone know what weight of oil to use? I'm assuming 15w unless otherwise informed.

Thanks.
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azraphale
Posted: Monday, April 12, 2010 4:03:43 AM

Rank: Administrator
Groups: Administration

Joined: 4/23/2008
Posts: 222
Location: Catskill Mtns.
While they can be done on the bike, it will be less work overall to simply jack up under the engine after removing the exhaust and take the whole front end off. It is very difficult to install the forks without binding if you try to keep the bike on its wheels and use a jack for assistance in getting the forks off the bike one at a time.

The factory calls for 5w15 fork oil, which I don't think I have ever been able to find. Straight 15w fork oil should be fine. Expect the front end to be a little stiff if you plan on riding the bike at temps below about 40 F, but not so bad that it's jarring.
| 1990 Kawasaki Zephyr 615 (Daphne) -=- 1986 Kawa Ninja 250 (stolen) |
| The Motorcycle Fuel Injection Handbook -=- http://tinyurl.com/297abo |
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Jason
Posted: Monday, April 12, 2010 5:24:28 AM
Rank: n00b
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Joined: 4/12/2010
Posts: 10
Location: Dorset, UK
Cheers, will let you know how I get on.
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