2005 ZX6R Fork Oil Chang - W/ Tips From Dave Moss
So as the title states, I'm going to show you how to change your fork oil in a 2005 zx6r, with some tips from Dave Moss' Video. Now this will work on the 05 and 06, but I'm guessing it will be the same for other years if they have the same type of forks.
Things you will need:
Triple tree stand, or some way to have the front end off the ground that isn't touching the tires or forks.
6mm Hex Socket along with Rachet
Adjustable wrench big enough to fit on the fork top plug
Something to drain the old fork oil out into that reads in mL
NEW fork oil (Manual recommends 5 weight)
So to start off, put the bike on the triple tree stand and remove the front tire. If you don't know how to do this, then I don't know if you should continue. lol
After removing the front tire go head and remove the front fender, along with both ram air covers.
In the first picture it shows you what to loosen.
1. Loosen the lower fork clamp bolts.
2. Loosen the handlebar bolt.
3. Go head and break loose the fork top plug.
4. Finally loosen the upper fork clamp bolt.
Make sure if there are any zip ties around wires holding onto the forks that you cut them.
Now push down on the top of the forks to get it started to remove, then start pulling from the bottom and twisting until you get it removed.
Now for the second picture.
Now that you have the fork tube out, push down on it and remember how it feels. It's important, but we'll get to that later.
Go head and loosen the fork top plug all the way.
Drain the fork oil into you container that has mL.
When the fork oil slows down, take the fork and have the sleeve all the way down and push down on the fork top plug so you can get the oil out of the cylinder. Do this a couple times and drain, and repeat. Now remember back in picture 2, when I said to press down on the forks and remember how it feels? This is where it comes into play. You should press down on the fork top plug until it feels like theirs no hydraulic resistance, just the spring coming back. When it is just dripping, then you have got 99.99% of the oil out.
So I've already shared with you some of Dave's tips, but here is the most important one. Look at how much fork oil you removed, this is how much you will be adding back.
Clean out your container with the old oil extremely well, add the new oil to it, and then add it to the forks, be sure to keep and eye on it so it doesn't go everywhere.
Now slide the fork tube sleeve back up to the top, add some grease to the fork top plug so its easier to remove next time, turn the fork top plug to the left until you hear it click into place and then tighten it back up.
Now put the fork on the ground and pump it until the oil gets in the cylinder and it feels normal again....
Now (fuck I say that alot) most people think your done, not if Dave has anything to say about it! He suggest that you polish the chrome on the fork tube itself. I didn't have any sandpaper to do this. If you want to, just do a quick search of what grade sandpaper you need. Also pull the dust seal down and add some grease around where the fork seal is. Push down easily about 2 inches a couple times and then push down far and hard once. Dave suggest that you do this at least every 1000 miles. Wipe off any excess grease. Put a little grease on the dust seal and pop it back in place.
Well your done now. Just reinsert the fork tubes into place and tighten everything back up. Make sure the fork tube is 6.5mm above the top triple tree. Lower tree bolts should be at 18ft lbs. Front fork top plug should be at 26ft lbs. Handlebar Bolt 18ft lbs. Top Tree bolt should be 15ft lbs.
This is my first write up. Hope I didn't miss anything...