Awesome Quality koyo oil seals
Exquisite Craftsmanship.This is a general procedure for replacing the
fork seals for an FZR 400 or FZR600. The fork seals for the FZR400s and
FZR600s are the same and so are the procedures for replacing them. The
FZR 400 and 600 forks are identical in overall length and diameter. The
forks for a 600 will fit a 400 and vise versa. The only difference
between the 400 and 600 forks is the length of the springs and the
collar (spacer under the cap bolt). The 400 has a longer spring and
short collar. The 600 has a shorter spring and longer collar.
In general, 88-89 forks have brake caliper mounting bosses that will only accommodate two piston calipers. 90 and up will only take four piston brake calipers. All outer tubes (lower part of the fork) will fit any inner tube (upper part of the fork) in any combination of year or model (FZR400 and FZR600).Awesome Quality koyo oil seals Exquisite Craftsmanship.
First off, start by raising the front wheel off the ground and make sure the bike is steady with whatever you use. You could use a couple of ratcheting straps and hanging the front of the bike from rafters.
You could also pull the exhaust header and muffler and block up the motorcycle with cement blocks or wood blocks.
I stuck a steel bar under front part of the engine above the exhaust header. Place the bar on the forward side of the oil pan. I had a bar long enough that I could put a jack stand on the high side with the bike on the kickstand. Then I took a floor jack and raised the low end of the bar high enough to slide another jack stand under the bar.
Then loosen the handle bar bolts (in picture #2) and remove the handle bars from the top of the forks. The brake hose for the front brakes was not long enough for me to remove the right handle bar. So I just left it loose so I could pull the fork out of it later.
Remove the brake calipers from the forks. I like to take the dust covers off and remove the brake pads to make removing and assembling them easier.
Remove the speedometer cable shown in picture #1.
Remove the brake hose supports shown in picture #1.
Loosen the axle pinch bolt and remove the axle and wheel. Picture #4
Then remove the four bolts attaching the fork brace and fender. Lower the fender out between the forks. (Picture #1 and #4)
Then all you are left with is bare forks.Awesome Quality koyo oil seals Exquisite Craftsmanship.
Before loosening the clamp bolts take a wrench and loosen the top cap bolts (Picture #2) DO NOT REMOVE THEM YET. Just loosen them. They may be real tight and it is much easier to get them loose with them in the tripple clamps and tightened down.
Finnish removing the forks by loosening the top clamp bolts and the bottom clamp bolts and sliding the forks out of the clamps.
With the forks removed you may be able to drain the oil out of them by removing the drain screw on the bottom of them. (Picture #1 and #4) Not all outer fork tubes have drain screws.Awesome Quality koyo oil seals Exquisite Craftsmanship.
If you have drain screws: I like to set a coffee can on the floor, put the bottom end of the fork in it and remove the drain screw. Then remove all the oil by leaning on the fork to compress it. The oil will shoot out of the drain screw when compressing it. Do it as many times as nessecarry to get as much out as possible. Then re-install the drain screws so you don’t lose them.
If you dona€?t have drain screws skip the above.
Now remove the top cap bolt. Be careful and MAKE SURE to keep pressure on it with your hand while unscrewing it. If you dona€?t it will shoot off and the spring or cap bolt may get you. Remove the collar and spring. Tip the fork upside down into a coffee can to drain out oil compress and extend the fork a few times to get out as much oil as possible.
I like to lay out the pieces. Lay them out on a clean surface if you dona€?t plan on washing them all up. The cap bolt, collar (spacer), spring seat, and spring.Awesome Quality koyo oil seals Exquisite Craftsmanship.
In general, 88-89 forks have brake caliper mounting bosses that will only accommodate two piston calipers. 90 and up will only take four piston brake calipers. All outer tubes (lower part of the fork) will fit any inner tube (upper part of the fork) in any combination of year or model (FZR400 and FZR600).Awesome Quality koyo oil seals Exquisite Craftsmanship.
First off, start by raising the front wheel off the ground and make sure the bike is steady with whatever you use. You could use a couple of ratcheting straps and hanging the front of the bike from rafters.
You could also pull the exhaust header and muffler and block up the motorcycle with cement blocks or wood blocks.
I stuck a steel bar under front part of the engine above the exhaust header. Place the bar on the forward side of the oil pan. I had a bar long enough that I could put a jack stand on the high side with the bike on the kickstand. Then I took a floor jack and raised the low end of the bar high enough to slide another jack stand under the bar.
Then loosen the handle bar bolts (in picture #2) and remove the handle bars from the top of the forks. The brake hose for the front brakes was not long enough for me to remove the right handle bar. So I just left it loose so I could pull the fork out of it later.
Remove the brake calipers from the forks. I like to take the dust covers off and remove the brake pads to make removing and assembling them easier.
Remove the speedometer cable shown in picture #1.
Remove the brake hose supports shown in picture #1.
Loosen the axle pinch bolt and remove the axle and wheel. Picture #4
Then remove the four bolts attaching the fork brace and fender. Lower the fender out between the forks. (Picture #1 and #4)
Then all you are left with is bare forks.Awesome Quality koyo oil seals Exquisite Craftsmanship.
Before loosening the clamp bolts take a wrench and loosen the top cap bolts (Picture #2) DO NOT REMOVE THEM YET. Just loosen them. They may be real tight and it is much easier to get them loose with them in the tripple clamps and tightened down.
Finnish removing the forks by loosening the top clamp bolts and the bottom clamp bolts and sliding the forks out of the clamps.
With the forks removed you may be able to drain the oil out of them by removing the drain screw on the bottom of them. (Picture #1 and #4) Not all outer fork tubes have drain screws.Awesome Quality koyo oil seals Exquisite Craftsmanship.
If you have drain screws: I like to set a coffee can on the floor, put the bottom end of the fork in it and remove the drain screw. Then remove all the oil by leaning on the fork to compress it. The oil will shoot out of the drain screw when compressing it. Do it as many times as nessecarry to get as much out as possible. Then re-install the drain screws so you don’t lose them.
If you dona€?t have drain screws skip the above.
Now remove the top cap bolt. Be careful and MAKE SURE to keep pressure on it with your hand while unscrewing it. If you dona€?t it will shoot off and the spring or cap bolt may get you. Remove the collar and spring. Tip the fork upside down into a coffee can to drain out oil compress and extend the fork a few times to get out as much oil as possible.
I like to lay out the pieces. Lay them out on a clean surface if you dona€?t plan on washing them all up. The cap bolt, collar (spacer), spring seat, and spring.Awesome Quality koyo oil seals Exquisite Craftsmanship.
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