FIZZER6
The Angry Blue Mantis
04-09 FZ6 FORK OIL and seal replacement - With Steering Head Bearing Swap!
We had a need for a FZ6 specific write-up on the front fork seal and oil replacement and I have until the end of February to get this done so may as well start now! This job gets you so close to the Steering Head bearings you may as well do that as well with ALL BALLS Steering Head bearing kit #22-1004
This is in progress as of Jan 22, 2015 and pictures will be added to the 1st several posts as things progress! Check back for updates!
First, TOOLS & SUPPLIES:
1. Fork oil (You need 1 Liter of Fork Oil) Stock is 0-2.5wt. I went with 5wt. You can safely go with 10wt if you want the front end to dive slower. The draw back is if you go too heavy on the fork oil your front end will not do as well on bumpy roads when leaned over due to slower rebound rates. 5wt. oil is a good compromise for riders under 200 lbs.
I went with Maxima. It's cheap on Ebay
2. Fork Seals and Fork Dust Seals. I would get a kit. OEM is expensive and ALL BALLS brand is only around $20 shipped so I went with them! The All Balls kit you want is part # 56-135
TOOLS:
1. screw drivers
2. assorted metric hex drives. Get the 3/8" socket type. Allen keys are a pain in the backside!
3. metric sockets and box end wrenches, 10mm, 12mm, 14mm are mostly what you will be using.
4. Large zip ties (to reattach your cables to the forks).
LET'S GET STARTED!
NOTE: YOU CAN SKIP TO STEP #5 IF YOU DO NOT WISH TO REMOVE THE FRONT FAIRING!
#1: Remove the seat. Remove the rear gas tank pivot bolt and the 2 allen bolts at the front edge of the tank, slide tank back, raise tank, support tank and replace pivot bolt.
#2: Remove inner fairing pieces (6 stainless round head allen bolts and 2 plastic screw clip under the mirror rubber bases).
This is the little plastic screw under the mirror rubber bases you must remove
#3: Disconnect the (2) wire harnesses on the LEFT side of the fairing. Note, you may need pliers to get the smaller harness disconnected. There is only 1 tab that has to be pried up and then the 2 halves of the connector will pull apart. If it's difficult I found it easier to remove the fairing and set it on a stand to the left of the forks and then disconnect the connector.
#4: Remove the (2), 12mm bolts that hold the fairing bracket to the triple-tree mount. Carefully remove the fairing.
Ignore the gray boxes mounted inside my fairing. Those are my HID ballasts for my dual bi-xenon projector headlights.
#5: ONLY IF YOU WILL BE REPLACING STEERING HEAD BEARINGS - break the upper steering stem nut loose. Cut the zip ties holding the cables and brake line to the upper forks. Break the upper fork clamps bolts loose but do not remove bolts yet.
(Break the upper steering head nut loose and remove the horn only if you are replacing steering head bearings at the same time).
#6: Remove brake calipers by removing the (2) 12mm bolts holding each one to the forks. Hang the brake calipers on the bike using bungees or wire to keep them from hanging on the lines.
#7: Remove pinch bolt for front axle from right fork. Use a 19mm male hex drive or the back end of a 19mm spark plug socket with 19mm wrench to loosen axle. Do not remove axle or wheel until you have supported the bike under the exhaust headers!
#8: Remove front fender. (1) Philips screw bolt and (1) 8mm bolt on each side. Set fender aside.
TO BE CONTINUED........................
We had a need for a FZ6 specific write-up on the front fork seal and oil replacement and I have until the end of February to get this done so may as well start now! This job gets you so close to the Steering Head bearings you may as well do that as well with ALL BALLS Steering Head bearing kit #22-1004
This is in progress as of Jan 22, 2015 and pictures will be added to the 1st several posts as things progress! Check back for updates!
First, TOOLS & SUPPLIES:
1. Fork oil (You need 1 Liter of Fork Oil) Stock is 0-2.5wt. I went with 5wt. You can safely go with 10wt if you want the front end to dive slower. The draw back is if you go too heavy on the fork oil your front end will not do as well on bumpy roads when leaned over due to slower rebound rates. 5wt. oil is a good compromise for riders under 200 lbs.
I went with Maxima. It's cheap on Ebay
2. Fork Seals and Fork Dust Seals. I would get a kit. OEM is expensive and ALL BALLS brand is only around $20 shipped so I went with them! The All Balls kit you want is part # 56-135
TOOLS:
1. screw drivers
2. assorted metric hex drives. Get the 3/8" socket type. Allen keys are a pain in the backside!
3. metric sockets and box end wrenches, 10mm, 12mm, 14mm are mostly what you will be using.
4. Large zip ties (to reattach your cables to the forks).
LET'S GET STARTED!
NOTE: YOU CAN SKIP TO STEP #5 IF YOU DO NOT WISH TO REMOVE THE FRONT FAIRING!
#1: Remove the seat. Remove the rear gas tank pivot bolt and the 2 allen bolts at the front edge of the tank, slide tank back, raise tank, support tank and replace pivot bolt.
#2: Remove inner fairing pieces (6 stainless round head allen bolts and 2 plastic screw clip under the mirror rubber bases).
This is the little plastic screw under the mirror rubber bases you must remove
#3: Disconnect the (2) wire harnesses on the LEFT side of the fairing. Note, you may need pliers to get the smaller harness disconnected. There is only 1 tab that has to be pried up and then the 2 halves of the connector will pull apart. If it's difficult I found it easier to remove the fairing and set it on a stand to the left of the forks and then disconnect the connector.
#4: Remove the (2), 12mm bolts that hold the fairing bracket to the triple-tree mount. Carefully remove the fairing.
Ignore the gray boxes mounted inside my fairing. Those are my HID ballasts for my dual bi-xenon projector headlights.
#5: ONLY IF YOU WILL BE REPLACING STEERING HEAD BEARINGS - break the upper steering stem nut loose. Cut the zip ties holding the cables and brake line to the upper forks. Break the upper fork clamps bolts loose but do not remove bolts yet.
(Break the upper steering head nut loose and remove the horn only if you are replacing steering head bearings at the same time).
#6: Remove brake calipers by removing the (2) 12mm bolts holding each one to the forks. Hang the brake calipers on the bike using bungees or wire to keep them from hanging on the lines.
#7: Remove pinch bolt for front axle from right fork. Use a 19mm male hex drive or the back end of a 19mm spark plug socket with 19mm wrench to loosen axle. Do not remove axle or wheel until you have supported the bike under the exhaust headers!
#8: Remove front fender. (1) Philips screw bolt and (1) 8mm bolt on each side. Set fender aside.
TO BE CONTINUED........................
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