Fork leak

  • TombstoneTom
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Fork leak

25 Feb 2025 10:29
#909378
So I drained and refilled my forks.  I put the minimum oil in and measured the level per the factory service manual to bring it to correct level. Now while it just sits, not even ridden, it's pushing oil out the top seal. To the point it made a small puddle on the ground. I'd like to think I didn't overfill it based on I followed the manual directions but possible.  What am I missing here? 
Thanks! Tom
1977 KZ400 A1 Deluxe

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  • Wookie58
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Re: Fork leak

25 Feb 2025 10:35
#909379
Even if "over filled" it shouldn't be coming out of there when just sitting !!

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  • DoctoRot
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Re: Fork leak

25 Feb 2025 12:03 - 25 Feb 2025 12:06
#909382
Hard to tell from the photo but looks like you put the fork seal in upside down.
Last edit: 25 Feb 2025 12:06 by DoctoRot.

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  • Cra-z1
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Re: Fork leak

25 Feb 2025 12:52
#909383
Yep seal is upside down. 

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  • Scirocco
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Re: Fork leak

25 Feb 2025 13:55
#909386
The tention spring in the oil fork seal should be on the botton side!
Some additionally dust seals add on top the primary oil fork seals have them on top to cover dust and water.

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  • Wookie58
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Re: Fork leak

25 Feb 2025 15:40
#909391
I'm not familiar with the 400 but the seals I just fitted in my ZX9R look almost identical from both sides (spring and lip both sides) the only give away is a slight chamfer on the outside of the leading edge and the inner lip on the driven side is approx 0.5mm lower than the outer edge ??

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  • TombstoneTom
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Re: Fork leak

25 Feb 2025 16:08
#909394
Well cool.  I just drained and refilled it. I didn’t change the fork seals.  I’ll put this with the other strange and unusual things I’ve come across with this bike. No wonder I got it for a song and dance. Y’all should see the starter….
As always, thanks everyone!
-Tom
1977 KZ400 A1 Deluxe

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  • sf4t7
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Re: Fork leak

25 Feb 2025 18:05
#909402
If previous owners knew some of the traps they inadvertently set for us, we'd say they were clever bastards.  
Scotty

1974 Z1A
Yoshimura 987 kit
welded Z1 crank
Andrews 1X Cams
Delkevic 4 into 1
Superbike bars
530 conversion

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  • Wookie58
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Re: Fork leak

26 Feb 2025 02:13 - 26 Feb 2025 02:58
#909410
Well cool.  I just drained and refilled it. I didn’t change the fork seals.  I’ll put this with the other strange and unusual things I’ve come across with this bike. No wonder I got it for a song and dance. Y’all should see the starter….
As always, thanks everyone!
-Tom
Has the "commutator "exploded" ??
If the starter clutch isn't disengaging correctly this is what happens. The starter is geared at approx 8:1 so 2400rpm at the starter = 300rpm engine cranking speed. If the clutch doesn't disengage once the engine fires then the engine drives the starter motor at a 1:8 ratio. This means 6000rpm engine speed = 48,000rpm starter speed, at which point centrifugal forces pull the segments out of the commutator (or the bearings seize and lock the motor) A lot of guys don't understand the potential consequences of a faulty starter clutch !!!!

Last edit: 26 Feb 2025 02:58 by Wookie58.
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  • TombstoneTom
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Re: Fork leak

26 Feb 2025 09:36
#909421
Excellent remedial lesson! Lol. No, it did not explode, all segments are intact. And the starter clutch is working perfectly.  Long story. It all started with the battery not charging.  Stator faulty,(10acv output and over 10ohms). So that led to disassembly of the cover.That led to my other post about the case being beat up, which I believe I solved that mystery. So while I was in there I figured I’d freshen up the starter, new o-rings, clean the com and new carbon brushes. I noticed the retaining ring on the output side was bent RED FLAG and grease from the output shaft. RED FLAG. Upon disassembly of the starter, some previous “mechanic” decided to (over) repack the reduction gear box. Which in turn pushed the grease past the seal into the electrical side, up through the armature and coated the carbon brushes.  So yeah. It’s been that kind of project. 
1977 KZ400 A1 Deluxe
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  • SWest
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Re: Fork leak

26 Feb 2025 10:13
#909425
Those fork tubes show signs of scuffing. You may be looking at buying new ones. 

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