ZXR400 Motorcycle Service Manual Supplement
Contents
1. spring preload see the Specifications Disassembly for each leg Loosen the top plug before removing the front fork Remove the front fork and then pour out the fork oil see Fork Oil Change OThe following parts are removed during draining the fork oil Top Plug Spring Seat Spring Guide Collar Main Spring Hold the fork tube horizontally in a vise Unscrew the Allen bolt and take a gasket out of the bottom of the inner tube A Inner Tube B Allen Bolt SUSPENSION 12 9 Take the piston cylinder unit from the top of the outer tube Do not disassembly the piston cylinder unit A Piston Cylinder Unit B Outer Tube Remove the following the outer tube Dust Seal Retaining Ring A Dust Seal B Retaining Ring Use the fork outer tube weight special tool to separate the outer tube from the inner tube OHolding the outer tube by hand pull the outer tube several times to pull out the inner tube 1 Inner Tube 3 Outer Tube 2 Weight 57001 1218 4 Pull 12 10 SUSPENSION OThe oil seal washer and guide bushings come off with the inner tube Remove the guide bushings washer oil seal retaining ring dust seal from the inner tube A Inner Tube Guide Bushing D Oil Seal B Outer Tube Guide Bushing E Retaining Ring C Washer F Dust Seal Assembly Replace the following parts removed with a new one Top Plug O Ring Guide Bushings Oil Seal Dust Seal If removed from the inne2. SUSPENSION 12 1 Suspension Table of Contents Exploded View Specifications Special Tools Front Fork Fork Oil Change Disassembly for each leg Assembly Inner Tube Inspection 3 Oil Seal and Dust Seal Inspection Spring Tension 12 2 SUSPENSION Exploded View i T1 TD x m 0e Caor C 2 T1 20 N m 2 0 kg m 14 5 ft lb T2 25 N m 2 5 kg m 18 ft lb T3 34 N m 3 5 kg m 25 ft lb T4 49 N m 5 0 kg m 36 ft lb T5 88 N m 9 0 kg m 65 ft lb T6 110 N m 11 0 kg m 80 ft lb M Apply molybdenum disulfide grease L Apply a non permanent locking agent to the threads SUSPENSION 12 3 12 4 SUSPENSION Specifications Item Standard Service Limit Front Fork Rebound damping setting Spring preload setting Fork oil Viscosity Amount per side Oil level fully compressed with spring Fork spring free length Rear Shock Absorber Rebound damping setting Spring preload setting Gas pressure 6 clicks counterclockwise from the seated position adjuster turned fully clockwise 6th mark from the top SAE 5W 424 25 mL 85 8 mm below from top of outer tube 325 1 mm No 2 of 4 position Spring free length minus 6 5 mm 980 kPa 10 kg cm 142 psi Non adjustable adjustable range 12 clicks adjustable range 7 marks Spring free length minus 6 5 mm to 24 5 Special Tools Steering Stem Nut Wre
3. e piston rod nut from the compressor push back the compressor until the nut positions in the wide slot of the compressor AWARNING To avoid serious injury never take out the compressor from the fork tube or at one procedure the spring seat and spring guide will jumping out of the piston rod causing crush your face or body O Lift up the compressor slowly on the piston rod and take it out from the fork tube Remove the spring seat spring guide and collar A Spring Seat B Spring Guide C Collar Hold the fork tube upside down over a clean container and pump it to drain the oil OThe main spring will come out at this time Remove the main spring gt RSL z2 A Push Rod C Container B Main Spring NOTE OTo discharge the fork oil pump the piston rod up and down at least ten times Pull the piston rod up above the outer tube top Tighten the piston rod nut finger tight O Check that the visible thread length is at least 16 mm and the chamfered side is down C Chamfered Side D Piston Rod A 16 mm or more B Piston Rod Nut install the main spring Hold the fork tube upright press the outer tube and the piston rod all the way down Fill the front fork to the top with the specified oil which is more than the specified amount Front Fork Oil Viscosity SAE 5W Amount per side 424 4 mL NOTE O While doing this take care to keep the oil level topped off so that it stays ab
4. mage If the damage is not repairable replace the inner tube Since damage to the inner tube damages the oil seal replace the oil seal whenever the inner tube is repaired or replaced CAUTION If the inner tube is badly bent or creased replace it Excessive bending following by subsequent straight ening can weaken the inner tube Oil Seal and Dust Seal Inspection If dust seal has any damage or wear replace it Replace the oil seal with a new one whenever it has been removed ty 1 Oil Seal 2 Dust Seal Spring Tension If the spring of either fork tube is shorter than the service limit it must be replaced If the length of a replacement spring and that of the remaining spring vary greatly the remaining spring should also be replaced in order to keep the fork tubes balanced for motorcycle stability 1 Main Spring 2 Free Length Fork Spring Length Standard 325 1 mm Service Limit 319 mm SUSPENSION 12 11
5. nch 57001 1100 SUSPENSION Fork Oil Level Gauge 57001 1290 12 5 B S PRE Aa ss Bearing Driver Set 57001 1129 Fork Piston Rod Puller M10 x 1 0 57001 1298 NS Fork Spring Compressor 57001 1338 ay Jack 57001 1238 Oil Seal amp Bearing Remover 57001 1058 as Fork Oil Seal Driver 57001 1288 12 6 SUSPENSION Front Fork Fork Oil Change Loosen the fork top plug temporarily Remove the front fork Hold the fork tube vertically in a vise Remove the fork top plug from the outer tube Compress the fork To loosen the piston rod nut fit the fork spring compressor special tool between the fork top plug and the spring seat then press the collar down until the compressor has just gone past the piston rod nut At this point push the compressor further toward the rod to fit it fully on the rod nut bottom Slide in the stopper of the compressor as far as it goes to secure the compressor Ca ors e M D m Le B A Piston Rod Nut D Fork Spring Compressor B Collar 57001 1338 C Stopper Use wrenches on the piston rod nut and the top plug to loosen the piston rod nut A Top Plug B Spring Seat C Piston Rod Nut D Collar Remove the top plug from the piston rod Slide out the stopper of the compressor Remove the compressor from the piston rod with the following procedures OTo made free th
6. ntil no more oil comes up the tube If no oil is drawn out there is not enough oil in the fork Pour in some more oil then draw out the excess Fork Oil Level Fully compressed with fork spring 85 8 mm If the oil is above or below the specified level remove or add oil and recheck the oil level Screw the fork push rod puller special tool onto the end of the rod install the collar so that the resin bush side is down A Resin Bush Put the spring guide and spring seat on the collar A Spring Guide B Spring Seat Using the fork spring compressor special tool press the collar down until the compressor has just gone past the piston rod nut A Fork Piston Rod Puller 57001 1298 B Fork Spring Compressor 57001 1338 Remove the fork push rod puller special tool Check the O ring on the top plug and replace it with a new one if damaged Screw in the rebound damping adjuster of the top plug so that the adjuster is 1 5 mm above the top plug 1 Rebound Damping Adjuster 2 1 5 mm Tighten the top plug finger tight While holding the fork top plug tighten the piston rod nut against the plug to the specified torque see Exploded View B Piston Rod Nut A Top Plug Remove the fork spring compressor special too Raise the outer tube and screw the top plug into it Tighten the top plug to the specified torque see Exploded View Adjust the rebound damping and
7. ove the four holes near the top of the inner tube 1 Holes 3 Inner Tube 2 Outer Tube Purge the air from the inner tube by gently moving the rod puller special tool up and down five times SUSPENSION 12 7 1 Piston Rod Puller 57001 1298 2 Outer Tube 3 Piston Rod Purge the air from between the inner and outer tubes by pumping the outer tube up and down Never extend the fork fully oil will be forced from between the tubes into the inner tube through the holes at the top of it This raises the oil level in the inner tube If the fork is extended to the full length of its normal travel the oil level will be raised about 30 mm 1 Never extend the fork fully After purging the air from the fork let it sit for about five minutes so that any suspended air bubbles can surface Measure the oil level using the fork oil level gauge special tool OSet the gauge stopper so that its lower side shows the oil level distance specified OWith the fork fully compressed insert the gauge tube into the inner tube and position the stopper across the top of the outer tube 12 8 SUSPENSION 1 Level Gauge 57001 1290 3 Oil Level Distance 2 Stopper 4 Outer Tube NOTE OThe gauge tube is graduated in 1 cm division OThe gauge body is graduated in 10 mL divisions excluding the gauge tube capacity about 5 mL O Pull the handle slowly to draw out the excess oil u
8. r tube Bottom Allen Bolt Gasket Cover the groove of the inner tube guide bushing with vinyl for installing a new oil seal and dust seal install the dust seal retaining ring and oil seal A Oil Seal B Retaining Ring C Dust Seal D Vinyl Remove the vinyl install the following onto the inner tube Washer Outer Tube Guide Bushing Inner Tube Guide Bushing When installing the inner tube into the outer tube put the washer on the outer tube guide bushing and tap the washer with the fork oil seal driver special tool until it stops 1 Fork Oil Seal Driver 57001 1288 2 Washer 3 Outer Tube Guide Bushing 4 Outer Tube nstall the oil seal into the outer tube using the oil seal driver special tool install the following by hand Retainer Dust Seal Hold the fork tube horizontally in a vise install the piston cylinder unit in the inner tube Apply a non permanent locking agent to the Allen bolt and tighten it to the specified torque see Exploded View Hold the fork tube vertically in a vise Press the outer tube and the piston rod all the way down install the main spring into the inner tube Pour in the specified type of oil and install the parts removed see Fork Oil Change Inner Tube Inspection If the inner tube is damaged replace it Nicks or rust damage can sometimes be repaired by using a wet stone to remove sharp edges or raised areas which cause seal da
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