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  1. #11
    FIZZER6 (OP)
    The Angry Blue Mantis FIZZER6's Avatar
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    Re: 04-09 FZ6 FORK OIL and seal replacement!

    Updates just added to Post #2. Ready to reassemble forks!
    Put my bike out on the highway
    feel that wind all in my face
    breathe some air that tastes like freedom
    let that be my saving grace
    I believe it's time for me to ride...

  2. #12
    FIZZER6 (OP)
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    Re: 04-09 FZ6 FORK OIL and seal replacement!

    BUMP: DONE! !!
    Put my bike out on the highway
    feel that wind all in my face
    breathe some air that tastes like freedom
    let that be my saving grace
    I believe it's time for me to ride...

  3. #13
    2 Da Street, Knobs R Gone FinalImpact's Avatar
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    Re: 04-09 FZ6 FORK OIL and seal replacement!

    Please ADD details: GREASE THOSE SEALS before installing them and protect the inner seal from damage during install. Both actions are critical to the longevity of the seal. i.e. pack the inner lips/registers with lithium soap base grease. It will extend their life.
    - Otherwise its like a knee on gym floor and then the seals leak in 9 months.
    Before installing the oil seal, cover the top of the fork leg with a plastic bag and slide the seal over the bag. It protects the oil seal during installation.

    Seal driver!
    Quote Originally Posted by FinalImpact View Post
    From: PVC Seal Driver came from (2015-01-22)
    I'm not sure if you have a proper seal driver but I made a hack tool which i used to use on MX forks. It also works on these 43mm forks.

    Our 43mm forks can have the seals and bushings driven in with 2" SCH40 PVC pipe (2.0" ID). Just take section to a band saw and cut a bunch of 4-5" slices up the pipe. With lots of slits in the pipe (longer than these), you can easily resize the sawed end by placing a hose clamp or zip tie around it. Use the top washer above the bushing to drive the bushing down. Its heavy gauge. The bushing itself is so thin it can slide under the PVC. Use an old seal to drive in a new seal. Its quick, easy, adjusts to different sizes, and it works!

    08 Raven w/a few mods...
    R6 Forks, R1 Rear Shock (revalved), 6 Ignition Advance, S1 CAT free Header, SS Mid-Pipe, 2Bro Exhaust, AIS block off plates, Bazzaz Z-Fi Fuel Controller & Z-AFM Data Logger, Air Box mod, CR10E Plugs, 48-Tooth Rear Sprocket, FZ1 Bars, Spider Grips, Adj levers, Powder Coated -Triple, Bars & Rear Sets, Solid mounted rear-sets w/knurled pegs, Dual Headlight, Tail Tidy, LED Combo Brake & Directionals, LED POD lights & Tinted PUIG Wind Screen!

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  5. #14
    FIZZER6 (OP)
    The Angry Blue Mantis FIZZER6's Avatar
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    Re: 04-09 FZ6 FORK OIL and seal replacement!

    Quote Originally Posted by FinalImpact View Post
    Please ADD details: GREASE THOSE SEALS before installing them and protect the inner seal from damage during install. Both actions are critical to the longevity of the seal. i.e. pack the inner lips/registers with lithium soap base grease. It will extend their life.
    - Otherwise its like a knee on gym floor and then the seals leak in 9 months.
    • Before installing the oil seal, cover the top of the fork leg with a plastic bag and slide the seal over the bag. It protects the oil seal during installation.

    Seal driver!
    Thanks! I would have added that note about the plastic bag from the service manual but the edges of my tubes were smooth as could be and will not damage the seal as long as you grease it and put it over easily. Good point though, not everyone may have the same results I did!

    Thanks for the tip about using a 2" piece of PVC like that to drive in the seals. Worked great!
    Put my bike out on the highway
    feel that wind all in my face
    breathe some air that tastes like freedom
    let that be my saving grace
    I believe it's time for me to ride...

  6. #15
    2007 FZ6 TownsendsFJR1300's Avatar
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    Re: 04-09 FZ6 FORK OIL and seal replacement!

    Excellent write up!

    Just a side note as I just changed the fork oil in my 07..

    The springs were installed from the factory (bought the bike from the original owner, my friend and I know they were't opened), the tighter spring coils were at the top...

    And for measuring the fluid once assembled; I took a long screwdriver, some masking tape on the screwdriver and marked off the correct, full level with a pen on the tape. Then, simply reach down with the screwdriver until it wicks up the oil and check your mark. Easily got them within 1mm of each other.

    I used the same oil you did but a 7 wt. Very happy with the oil pick, forks work noticably better..
    Scott
    2007 Yamaha FZ6- BD43 headlight mod, PIAA bulbs, Stebal air horn, Scorpion SS pipes-(no DB killers), Speedohealer, HEL SS brake lines, Fenda Extenda, K&P SS re-usable oil filter, custom mounted BMW style electrical outlet(L.S.), Techmount GPS mount with handlebar bar risers/set backs, additional helmet lock, custom mod'ed seat(Spencers), Hyper light-rear running/brake light, custom radiator/fan protector, Techspec tank pads, Grip Puppies, Yamaha rear rack with custom aluminum flat rack.

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  8. #16
    FIZZER6 (OP)
    The Angry Blue Mantis FIZZER6's Avatar
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    Re: 04-09 FZ6 FORK OIL and seal replacement!

    Quote Originally Posted by TownsendsFJR1300 View Post
    Excellent write up!

    Just a side note as I just changed the fork oil in my 07..

    The springs were installed from the factory (bought the bike from the original owner, my friend and I know they were't opened), the tighter spring coils were at the top...

    And for measuring the fluid once assembled; I took a long screwdriver, some masking tape on the screwdriver and marked off the correct, full level with a pen on the tape. Then, simply reach down with the screwdriver until it wicks up the oil and check your mark. Easily got them within 1mm of each other.

    I used the same oil you did but a 7 wt. Very happy with the oil pick, forks work noticably better..
    Thanks for the comment. My 2006 main springs came out of the forks with the tighter coils on the BOTTOM and I bought the bike brand new. Either my forks were assembled wrong from the factory or the 04-06 bikes had the springs in reversed.
    Put my bike out on the highway
    feel that wind all in my face
    breathe some air that tastes like freedom
    let that be my saving grace
    I believe it's time for me to ride...

  9. #17
    2007 FZ6 TownsendsFJR1300's Avatar
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    Re: 04-09 FZ6 FORK OIL and seal replacement!

    Quote Originally Posted by FIZZER6 View Post
    Either my forks were assembled wrong from the factory or the 04-06 bikes had the springs in reversed.
    Page 4-54 in the S1 YAMAHA shop manual shows the tighter spring end atop too.

    I suspect someone wasn't paying attention (or it was a Friday) when they assembled your forks at the factory... Stranger things have come out of the factory....


    Actually, if you think about it, the top, tighter winds (if at the top), DON'T MOVE nearly as much as the lower part of the spring which is directly supporting the lower fork tubes / axle / wheel.. Progressive action as the forks compress.

    If there was any noticable different feel, I would think it would be slightly stiffer (as your bike currently is set up)..
    Scott
    2007 Yamaha FZ6- BD43 headlight mod, PIAA bulbs, Stebal air horn, Scorpion SS pipes-(no DB killers), Speedohealer, HEL SS brake lines, Fenda Extenda, K&P SS re-usable oil filter, custom mounted BMW style electrical outlet(L.S.), Techmount GPS mount with handlebar bar risers/set backs, additional helmet lock, custom mod'ed seat(Spencers), Hyper light-rear running/brake light, custom radiator/fan protector, Techspec tank pads, Grip Puppies, Yamaha rear rack with custom aluminum flat rack.

  10. #18
    FIZZER6 (OP)
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    Re: 04-09 FZ6 FORK OIL and seal replacement!

    Quote Originally Posted by TownsendsFJR1300 View Post
    Page 4-54 in the S1 YAMAHA shop manual shows the tighter spring end atop too.

    I suspect someone wasn't paying attention (or it was a Friday) when they assembled your forks at the factory... Stranger things have come out of the factory....


    Actually, if you think about it, the top, tighter winds (if at the top), DON'T MOVE nearly as much as the lower part of the spring which is directly supporting the lower fork tubes / axle / wheel.. Progressive action as the forks compress.

    If there was any noticable different feel, I would think it would be slightly stiffer (as your bike currently is set up)..
    The good news is I can swap the spring direction at any time without having to disassemble the forks from the bike by taking the weight off the front tire, removing the fork end caps and using a magnet wand to bring the spacer, washer and spring out.

    It makes more sense to me to have the tighter coils at the bottom since the tighter coils compress faster than the stiffer coils it would give the wheel a softer initial hit when absorbing bumps and then the spring rate would become progressively stiffer as the spring compressed further. Otherwise as the fork compresses the spring is being compressed with the same force on both ends as the compression of the fork is driving the spring agains the spacer and washer wish is held on by the end cap. I really doubt I'll notice any difference if I reversed them.
    Put my bike out on the highway
    feel that wind all in my face
    breathe some air that tastes like freedom
    let that be my saving grace
    I believe it's time for me to ride...

  11. #19
    2007 FZ6 TownsendsFJR1300's Avatar
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    Re: 04-09 FZ6 FORK OIL and seal replacement!

    Quote Originally Posted by FIZZER6 View Post
    The good news is I can swap the spring direction at any time without having to disassemble the forks from the bike by taking the weight off the front tire, removing the fork end caps and using a magnet wand to bring the spacer, washer and spring out.

    It makes more sense to me to have the tighter coils at the bottom since the tighter coils compress faster than the stiffer coils it would give the wheel a softer initial hit when absorbing bumps and then the spring rate would become progressively stiffer as the spring compressed further. Otherwise as the fork compresses the spring is being compressed with the same force on both ends as the compression of the fork is driving the spring agains the spacer and washer wish is held on by the end cap. I really doubt I'll notice any difference if I reversed them.
    Agreed, I don't think you'd feel any difference however I have to disagree re the coils. The wider space will compress (and be softer) than the tighter winds.

    Thus having the tighter winds at the top really only compress (to speak of) when near the end of its travel (bottoming out)..

    With the front end supported, gently raising the ft wheel (2x4's under the tire) will pop out the spacer/washer and spring. I'd just do it real slow as to NOT loose any oil to speak of. Re-measuring would necessitate the forks be absolutly verticle..
    Scott
    2007 Yamaha FZ6- BD43 headlight mod, PIAA bulbs, Stebal air horn, Scorpion SS pipes-(no DB killers), Speedohealer, HEL SS brake lines, Fenda Extenda, K&P SS re-usable oil filter, custom mounted BMW style electrical outlet(L.S.), Techmount GPS mount with handlebar bar risers/set backs, additional helmet lock, custom mod'ed seat(Spencers), Hyper light-rear running/brake light, custom radiator/fan protector, Techspec tank pads, Grip Puppies, Yamaha rear rack with custom aluminum flat rack.

  12. #20
    FIZZER6 (OP)
    The Angry Blue Mantis FIZZER6's Avatar
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    Re: 04-09 FZ6 FORK OIL and seal replacement!

    Quote Originally Posted by TownsendsFJR1300 View Post
    Agreed, I don't think you'd feel any difference however I have to disagree re the coils. The wider space will compress (and be softer) than the tighter winds.

    Thus having the tighter winds at the top really only compress (to speak of) when near the end of its travel (bottoming out)..

    With the front end supported, gently raising the ft wheel (2x4's under the tire) will pop out the spacer/washer and spring. I'd just do it real slow as to NOT loose any oil to speak of. Re-measuring would necessitate the forks be absolutly verticle..
    I thought the same thing. Until I tested it. when I compress the tighter coiled end of the spring it compresses about twice as much as the end of the spring with the looser coils when the same force is applied on that end.
    Put my bike out on the highway
    feel that wind all in my face
    breathe some air that tastes like freedom
    let that be my saving grace
    I believe it's time for me to ride...

 

 
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