SDC Performance UK News

7 June 2013

Kawasaki ZXR400 race project - DAY 5

Well the forks have been totally stripped over the last 2 days , I must say they were in a hell of a mess. Once stripped we could assess thm properly. Both fork oil and dust seals were rusty and leaking , fork stantions were covered in paint overspray and dirt build up , the damper unit that controls the rebound damping in these forks was so gunged up that it kept seizing solid.

 

ZXR400 rebuild

 

It took a good 30-40 mins of working the damper unit and flushing with brake cleaner , but eventually we managed to remove all of the gunge and built up crud. The fork caps had to be soaked in paint thinners to break down the beautiful green paint work !! These had to be totally stripped to component level and every individual part cleaned , corrosion removed and polished , then all re greased and assembled to get the caps working properly.

As this is for race use we have have upped the fork oil weight to 10w and used Rock Oil competition fluid. The air gap was set to 90mm and new fork oil and dust seals. While apart we also gave the outer stantions a new gold finish , the lower stantions were polished and the bottoms given a new finish in black. Both forks feel like they now have a much stronger damping for the track and look like new , all adjusters now work exactly as they should ... Forks ... Job done

 

ZXR400 forks rebuilt

Category: General News
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