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Pinned Fitting New Fork Seals - ZXR250A

Discussion in 'Kawasaki 250cc In-line 4's' started by Timothy Verma, Jan 16, 2014.

  1. Timothy Verma

    Timothy Verma Member

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    So I finally had the time and resources to change the leaking fork seals on my zxr250a.

    Here are a few pics of how I got them done. Had to improvise on a few things because its hard to find everything you need here.

    Had to use heavy duty ratchet straps to hang the ninja since I could not get any jacks or stands. I thought this would be the best way.
    IMG_2443.jpg

    The old dust seals were damaged and the oil seals gave up as well. These seems to still have original seals and by the looks of it the oil and seals were never changed before.


    IMG_2446.jpg IMG_2449.jpg IMG_2448.jpg

    So after hanging the ninja and getting the forks out I started to take apart the forks. (I loosened the top cap while the forks were still on the bike)

    I used small ratchet straps to compress the spring to get the top off. ( I had to sharpen the tip of the hooks on the straps to make sure they would fit the two wholes on the top properly and not slip off)
    IMG_2492.jpg

    I used an old bolt to lock the nut from the rod so that it would not drop all the way down and I could pull it up easily.

    IMG_2477.jpg

    Old seals after taking off the outer tube. (Just had to pry out the dust seals, clip and then slide the inner and outer tube a few times to knock the seals and washer)
    IMG_2482.jpg IMG_2471.jpg

    The oil was nasty! I let the forks drain out properly and cleaned the springs and tubes.
    Used a latex glove to get the new seals in without damaging it.
    IMG_2483.jpg

    I used the old seal as the seal driver to make sure everything was seated properly. (Just chopped off a section of the seal and used a light hammer to drive the seals in)
    IMG_2489.jpg
    (it got bent real bad while i was taking it out but with a section chopped off just slide this on top and knock the new seals in place)

    New seals in place. Once done, I filled the oil using specifications from the manual.

    IMG_2487.jpg

    Sorry I could not take more pics. Hope this helps if anyone is planning on changing the seals themselves.

    Feel free to message me if you have any questions or if I can help in any way. I will be more than happy to do so.
     
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  2. GreyImport

    GreyImport Administrator Staff Member The Big Cheese Contributing Member

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    Great writeup and pics :thumb_ups:
     
  3. Timothy Verma

    Timothy Verma Member

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  4. DamnitLaverty

    DamnitLaverty Whattanoob! Premium Member

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    This is awesome. Fork seals are the latest thing to fix on my bike, and I've never torn apart inverted forks. Thanks for taking the time to take pics!!
     
  5. Linkin

    Linkin The Apprentice Premium Member Dirty Wheel Club Contributing Member

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    Only thing I will add is that after filling the fork with the amount of specified, some forks (like BMW S1000R/RR) need to be bled up and then have the oil height checked, then add/remove oil to get the correct oil height. Specs should be in the service manual for the ZXR.
     
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  6. DamnitLaverty

    DamnitLaverty Whattanoob! Premium Member

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    I have one of those!
     

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