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 fork seal nightmare

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Posts : 18
Join date : 2011-01-19

PostSubject: fork seal nightmare   Sat Nov 26, 2011 12:35 pm

Hi guys does anyone out there know anything (more than me anyway) about the kawasaki gpz550 front fork setup.

done the fork seals twice now! the first time it went pear shaped because i was using a punch to seat the seals rather than some tube.

first time they p***ed oil everywhere soon as i put them together

second time i did them the right way,passed the mot ok and everything been ok for about 2 weeks.

just went out this afternoon for a tinker with the carbs (got a flat spot at 5k suspect dirt in carb) and there is a gurt puddle of oil under both forks and oil p***ing out around the seals.

i know the gpz has a weird air and spring suspention and i had to pressurise the forks at about 8psi when i rebuilt them.

can anyone shed anymore light on the problem?
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Posts : 96
Join date : 2011-10-26
Age : 53
Location : Feltham, England

PostSubject: Re: fork seal nightmare   Sat Nov 26, 2011 12:45 pm

Did you check the stanchions for pitting / scoring ?,have you over filled with fork oil ?, if they are the correct seals as per the model and you have fitted them correctly the only other thing that comes to mind is have the stanchions been re-ground and re-chromed, the diameter might differ slightly from the original and allow oil to get past the seal, we are talking micro millimeters but thats all it would take
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Join date : 2011-01-19

PostSubject: Re: fork seal nightmare   Sat Nov 26, 2011 3:15 pm

Yes, there is some pitting on the forks, but it appears not to be low down as the lower end where the seals are.

I did also slightly overfill with oil, the haynes manual perscirbes 200cc of oil but after I filled them the forks were not smooth so I put another 50 in and they were then smooth.

I was wondering if its the air pressure forcing the oil out I cannot see from the diagram what is meant to seal the air in surly it can't be just the oil seals can it?

Any advise on these systems would be greatfully recived
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gone fishin

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Join date : 2011-10-26
Location : black country

PostSubject: Re: fork seal nightmare   Sun Nov 27, 2011 5:49 am

what do u mean by smooth all the oil does is offer resistance if its not "smooth "then there must be a problem with its assembly ,the travel should be between 160 - 170mm try decreasing the amount of oil but selecting a heavier grade instead ,this will stiffen the frontend and will alter the travel to 130-140mm

as for the leaking i agree with oncas with even the smallest of imperfections the oil will seap ,are the seals seated right ? have the new seals been damaged in anyway
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