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  • 9 Post By accuengineer
  • 1 Post By The Monk

Thread: Fork Servicing - FZS

  1. #1
    Passionate D.I.Y Guy accuengineer's Avatar
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    Default Fork Servicing - FZS

    Hai

    Till now all the DIY I had done was by using normal or off the shelf tools. This DIY has literally made me re-invent the wheel. Mainly the special tools that was required for the job.

    Tools required.

    1. Spanners/sockets 10,12,14, 17,19 & 22mm
    2. Allen key socket 5mm
    3. Special tool for opening the damper rod made by using a rod and 23 Hexagon nut.
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    4. Special tool oil seal assembling tool. I used basically a old cap but a plastic pipe will be the ideal choice.
    5. Flat screw driver
    6. Star screw driver

    Spares required

    1. Oil seal 2 nos Rs. 250 each
    2. Fork oil Motul/HP - 459 ml/fork
    3. Damper springs - preferred to be changed Rs. 90 each

    Procedure:

    1. Before starting the DIY spread lot of old news paper on the work area, as old oil from the forks tends to get spilled on the floor.
    2. Remove the front wheel using spanner.
    3. Remove front brake assembly using 12mm Spanner
    4. Remove the front mudguard using 10mm spanner and star screw driver.
    5. Remove the side headlight guard where the indicators are fixed to enable to remove the bolts holding the front forks.
    6. Loosen the bolts in top and bottom using a 10mm and 14 mm spanner. Caution - the fork will slide down and can get damaged. Hence first loosen the top 10mm bolt and the loosen the 14.00mm bolt.
    7. Do not remove the fork completely. Temporally slide the top of the fork to the 14.00mm bolt and tighten then 14.00mm bolt. Now using a 22.00mm ring spanner loosen the screw cap of the fork. Use only ring spanner as the part is made of Aluminium open spanner tends to slip easily and can cause damage.
    8. Now loosen the 14.00mm bolt and remove the fork completely from the bike.
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    9. Now slowly remove the screw cap as it can jump out due to spring tension. Clean the screw cap, o-ring and the pressure plate. Check whether the O-ring is brittle, if found brittle replace.
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    10. Remove the spacer and clean.
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    11. Now slowly empty the fork oil by keeping one finger inside the tube to stop the washer and the spring from dropping into the bowl. Remove the washer and the spring. Clean the washer and replace with new spring.
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    12. Now invert the fork and start pumping in order to remove the remaining oil.
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    13. Insert the 5 mm socket from the bottom and open the allen screw. Note the allen screw will be tight if this is the first time you are removing the screw. Since there will be thread sealant applied on the allen screw for better sealing. Once the allen screw is loose, insert the special tool which is to be fabricated to hold the damper rod. Now remove the allen screw along with the copper washer completely and clean it.
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    14. Remove the damper rod and rebounce spring(Small) and clean them.
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    15. Now remove the dust cover using the flat screw driver. Caution do not exert excess pressure as the screw driver can touch the inner tube and can scratch the same.
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    16. Now remove the locking clip using a screw driver. Caution do not exert excess pressure as the screw driver can touch the inner tube and can scratch the same.
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    17. Now the tube will freely move inside tube housing but will not come out due to the presence of oil seal. Now hold firmly both the tubes and gentle try to remove the inner tube by pulling. After few tries the inner tube will come out along with the oil seal. Remove the oil seal and oil seal washer and clean them.
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    18. Clean all the components with diesel and dry them naturally.

    Re-assembling:

    1. Insert the oil seal washer into the inner tube. Note: there will be molybdenum coating in the outer surface of the washer so dont use any abrasives to clean them. Then apply some thin grease in the inner surface of the oil seal and put a plastic cover over the top of the inner tube. This is to prevent the oils seal from getting damaged due to the sharp corners of the inner tube. Once inside slide the oils seal down. Note: The letter/numbers on the oil seal should be in the top while assembling
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    2. Now insert the whole assembly into the outer tube. Now by using the special oil seal tool (plastic pipe/cap) gentle tap evenly to insert the oil seal and washer. Stop when you see the grooves for the oil seal clip.
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    3. Now insert the oil seal clip using a flat screw drive. Caution do not exert excess pressure as the screw driver can touch the inner tube and can scratch the same.
    4. Now insert the dust cap.
    5. Now insert the damper rod along with the rebounce spring(Small) inside the inner tube. Hold the damper rod with the special tool from one side and tighten the allen bolt from the other side. (Apply 28Nm torque).
    6. Now insert the new spring and then followed by the spring washer.
    7. Now insert the spacer. Lift the inner tube to the full length and start pouring the fork oil. Measure 459 ml of fork oil and pour inside. Warning: If you pour more or less oil. The fork could behave erratically. Hence always measure the correct amount and fill equally in both the forks.
    8. Now insert the pressure plate and the screw cap along with the O-ring. Note: Slight pressure has to be applied since the springs are new. Press and screw the screw cap slightly so that it catches the thread.
    9. Now tighten the screw cap using a 22 mm socket.
    10. Now reassemble the fork the similar way we had removed them. Warning: Slide the fork into the clamps so that it flush with the surface. Do the same for the other fork also and check whether both are in the same height.
    11. Now assemble the front mud guard, disc brake assembly and the wheel the same way we had removed them.

    Test ride the bike slowly and fully apply the Front brake at slow speed. Check whether it is pulling to a side. If so then check the height of the forks. If all is well Voila enjoy you ride.

    Disclaimer - Please take all the precautions and warnings mentioned. And any damage or injure caused by trying this procedure is purely up to you and I am not responsible if any thing happens.

    Cheers

    Mathews

    Smile at everyone you meet and make someone happy.

    Its better to sweat than bleed!! "AGATT "




  2. #2
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    Default Re: Fork Servicing - FZS

    DIY Approved

    Thanks for this. Though a bit complicated for the first timer
    accuengineer likes this.
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    Default Re: Fork Servicing - FZS

    Dear
    recently my mechanic has reassemble Front Fork of my FSZ and he pour 150ML of fork oil at each fork is it ok.

  4. #4
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    Default Re: Fork Servicing - FZS

    150ml its very less....mine mechanic poured 300ml in each fork

  5. #5
    Passionate D.I.Y Guy accuengineer's Avatar
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    Default Re: Fork Servicing - FZS

    Quote Originally Posted by Prince_Haider View Post
    Dear
    recently my mechanic has reassemble Front Fork of my FSZ and he pour 150ML of fork oil at each fork is it ok.
    Hai

    As per Service manual, the required quantity of fork oil per fork is 459cm3 or 459ml of fork oil. If you pour less or more oil the forks either be soft or hard. And one main thing to be kept in mind is that equal amount of fork oil should be poured as this will create stability issues while riding the bike.

    Cheers

    Mathews

    Smile at everyone you meet and make someone happy.

    Its better to sweat than bleed!! "AGATT "




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