need fork tools - Kawasaki Versys Forum
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post #1 of 41 (permalink) Old 04-30-2010, 12:31 AM Thread Starter
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need fork tools

hi,
i want to change my fork oil, and remember a while back Invader listed some part numbers of some recommended tools to use.

would anyone have these tools & parts numbers ?

i've done a search with no luck.

i appreciate the help guys, thx.

dave
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post #2 of 41 (permalink) Old 04-30-2010, 05:14 AM
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Oh yeah, I meant to tell you...
You'll need a spring compressor and spring stopper tool. You can get the set from Traxxion Dynamics for $36.95: http://traxxionstore.com/detail-25.aspx
You also need a fork rod puller to reassemble. Traxion has a universal one for $24.95: http://www.traxxion.com/detail-16.aspx

You can get Kawasaki part # 57001-1298. It used to be listed in Kawasaki OEM parts distributors, but now I only see it here for $16.76 ($18.74 MSRP): http://speedsupplies.com/partslistin...00&category=KW

Or you can get this complete kit: http://www.traxxion.com/detail-12.aspx

Which fork oil are you planning to use?
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post #3 of 41 (permalink) Old 04-30-2010, 09:53 AM Thread Starter
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thx bud for all the info, very much appreciated.

not sure on on the oil.

i do have a Elka rear shock, which i bought and have set up mostly to remove those high compression hits on the road, like expantion joints, those really bother my back.

what would you suggest for fork oil ?
what is stock weight ?

i weigh 185lb with gear, and do no off road riding with it.

i am going to start doing track days with it, but i can stiffen everything then.

really want to smooth out those expantion joints when i have compression backed out. it'd pretty darn good now with the front backed out, and the new Elka.
just want to keep clean oil in it.

dave

Last edited by dhauch; 04-30-2010 at 01:42 PM.
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post #4 of 41 (permalink) Old 04-30-2010, 05:28 PM
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do the revalve. your back will thank you.
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post #5 of 41 (permalink) Old 04-30-2010, 05:57 PM Thread Starter
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Originally Posted by tomla View Post
do the revalve. your back will thank you.
i'm game, what does it consist of ?

dave
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post #6 of 41 (permalink) Old 05-01-2010, 10:44 AM
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post #7 of 41 (permalink) Old 05-01-2010, 09:01 PM Thread Starter
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[QUOTE=Phoneman064;79234]Try this thread.

http://www.kawasakiversys.com/forums...ead.php?t=7435[/QUOTE

thx.

what is the stock oil weight ?

dave
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post #8 of 41 (permalink) Old 05-02-2010, 12:17 AM
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Stock fork oil is SHOWA SS-8 or equivalent SAE 10W.

Amsoil has excellent synthetic Shock Therapy 10W suspension fluid with a 205 viscosity index: http://www.amsoil.com/StoreFront/stm.aspx
Available in 5W: http://www.woodsbrosracing.com/amsoil/stl.htm

You can get any Amsoil product from http://www.woodsbrosracing.com/amsoil-online-store.htm at over 20% off with promo code.

There's also Maxima's Racing Fork Fluid in 5W, 7W, 10W and 15W: http://www.maximausa.com/products/su.../forkfluid.asp
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post #9 of 41 (permalink) Old 05-13-2010, 07:45 PM Thread Starter
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how many ounces of oil do i put back in my forks, or is fork ?

looking for the stock amount.

thx,
dave
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post #10 of 41 (permalink) Old 05-13-2010, 08:24 PM
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Wanted to pass on a tip I learned on setting the oil level. Don't set this by volume, set by distance from top.

Buy a 99 cent turkey baster, or borrow one from your kitchen. Mark the desired oil level on the baster measuring from the tip. Holding your fork tube vertically, and fully compressed, insert the baster in the top of the fork tube up to the marked line and suck out the excess oil. Presto, oil level is set accurately.
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post #11 of 41 (permalink) Old 05-13-2010, 08:27 PM Thread Starter
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how far from the top of the tube is the oil suppose to be, stock ?

dave
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post #12 of 41 (permalink) Old 05-13-2010, 11:06 PM
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I needed nearly 1 liter total for both forks after a thorough draining and cleaning.

Right Fork Leg Approx. 410 mL (13.9 US oz.) (when changing oil)
478 2.5 mL (16.2 0.084 US oz.) (after disassembly and completely dry)
Left Fork Leg Approx. 415 mL (14.0 US oz.) (when changing oil)
487 2.5 mL (16.5 0.084 US oz.) (after disassembly and completely dry)
Fork Oil Level:
Right Fork Leg 75 2 mm (3.0 0.08 in.) (fully compressed, without fork spring, below from the top of the outer tube)
Left Fork Leg 65 2 mm (2.6 0.08 in.) (fully compressed, without fork spring, below from the top of the outer tube)
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post #13 of 41 (permalink) Old 05-13-2010, 11:18 PM Thread Starter
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thank you so much invader.

dave
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post #14 of 41 (permalink) Old 05-14-2010, 12:00 AM
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Using a notched allen key as a dip-stick worked well for me... I made myself a big 'Q-Tip' by taping a piece of clean cloth at the end of a long paint brush to clean out all the black bushing and spring wear residue in the fork tubes, after leaving them upside down for a while for a good draining. The springs and spring spacers can be wiped clean inside and out as well.
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post #15 of 41 (permalink) Old 05-14-2010, 12:53 AM
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Also compress and decompress the fork tube a few times first to work out any air bubbles before setting the oil level. I have not looked a Versys service manual but when I did this on my Ninja it was the same level on both forks, just seems weird it would be different on each leg. The reason for setting the level is the air space at the top acts as a spring.
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post #16 of 41 (permalink) Old 05-14-2010, 01:39 PM
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Quote:
Originally Posted by dhauch View Post
hi,
i want to change my fork oil, and remember a while back Invader listed some part numbers of some recommended tools to use.

would anyone have these tools & parts numbers ?

i've done a search with no luck.

i appreciate the help guys, thx.

dave

FYI I did the job on my fork a few month ago.

I built my own tools.


For the piston rod puller:

A simple piece of pipe 1/8" WITH THE INSIDE threaded M10X1,0 with a cheap tap set that I had.

Spring stopper:


I took a small connecting plate from the local hardware store, drilled a 3/8'' hole and opened it with a grinder, I bent it on a vise.

Spring compressor tool:





Used this contraption built from 1/2'' pipe fittings with 2 levers stuck under my workbench, don't ask me to explain but I was able to perform the job alone.

I think you're better off with a black ABS pipe union using and two eye bolt and an extra pair or arms

To check the oil level:



To remove oil from the fork, I used a syringe for oral medication from the local drugstore


I Used Motul 15W oil but I find that the fork are harsh on rough rodes. I think most would be better off sticking to grade 10 or grade 8

Charles Leblanc
2007 Versys
Givi Windshield and side case
Montreal, Quebec, Canada

Last edited by charlesleblanc; 05-14-2010 at 05:23 PM.
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post #17 of 41 (permalink) Old 05-14-2010, 02:11 PM
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Found this some time ago. Not sure how acurate it is but worth a look.

http://video.mpora.com/watch/Je4gKpr11/

Falling down is your bodies way of saying you just screwed up.

IBA# 38547
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post #18 of 41 (permalink) Old 05-14-2010, 04:25 PM
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Quote:
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Found this some time ago. Not sure how acurate it is but worth a look.

http://video.mpora.com/watch/Je4gKpr11/
I looked at the video

The fork looks alot like the Versys fork and the oil change procedure is much simpler.

The only drawback is that you need to measure the oil carefully. The fork oil change method from the user manual is more complex but you can measure the oil level with a ruler.

Charles Leblanc
2007 Versys
Givi Windshield and side case
Montreal, Quebec, Canada
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post #19 of 41 (permalink) Old 05-15-2010, 05:45 PM
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next weekend i ll do the valve clearence check and the suspension maintenance...tough weekend! 1 lt of synth oil for the front mast be enough ,i am gonna buy some things these days to be prepared...any tips of the last moment?
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post #20 of 41 (permalink) Old 05-17-2010, 10:35 AM
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Invader do I need the "tools" if I am just changing the oil and not planning on wiping down the internal surfaces? On that note...will it be as easy as the Video above seems to show?

Integrity is doing the right thing, even if nobody is watching.
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