Author Topic: ZRX Front End Replacement  (Read 16498 times)

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Offline Dave Scott

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Re: ZRX Front End Replacement
« Reply #75 on: May 23, 2012, 04:31:40 pm »
I have them a couple mm below the top of the triple at this point.  I won't try tinkering too much until I get a good tire so i have a stable setup to test with.  Fork seal repair first.   ::)

Offline Dave Scott

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Re: ZRX Front End Replacement
« Reply #76 on: June 19, 2012, 03:04:20 pm »
So, I finally had a chance to do the remaining work on the front end to fix things up.  The good news is that after installing a Michelin Power Pilot in place of the worn out BT014, the front end and steering feel superb.  The fall in and heaviness of steering in the front was due to the old tire.  I'm quite pleased with the front end now with good rubber on them.  The suspension feel is firm but not harsh at all.

The bad news....I replaced the fork seal, but still leaking.  Upon further inspection, I found a burr about an inch above the rubber dust seal.  I can get another used fork for about 70 bucks, but does anyone have any success stories doing a repair?

Offline GF-in-CA

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Re: ZRX Front End Replacement
« Reply #77 on: June 19, 2012, 03:26:49 pm »
How much of a burr is it?  If it sticks out from the surface, you can use a file to get it flush with the surface, then use fine sandpaper to smooth it out.  If it is a divot, I've heard of people using epoxy to fill the depression, then file flush and sand.  You can then orient the repair to the side so the bushing doesn't put a lot of force on it.  The main thing is to get it so the seal doesn't catch on it and get damaged.  I've had some minor burrs on some dirt bike forks, and the file down/ sand method worked fine.

HTH,
Gary F.

1998 ZGX1100
Central Valley California

Offline WillyP

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Re: ZRX Front End Replacement
« Reply #78 on: June 19, 2012, 03:29:30 pm »
You mean a burr on the chrome of the fork tube? You can try polishing the tube, even if you can't remove the burr completely, knock it down so it doesn't damage the new seal. When I worked in a hydraulics shop we would put the rods in a lathe and while spinning, hold a fine grit against them, slowly moving from end to end. I have done the same with my '01 forks by chucking the preload adjuster in a drill and using that to spin the fork tube, with the other end supported on a table with a rag.

« Last Edit: June 20, 2012, 08:15:00 pm by WillyP »
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Offline Dave Scott

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Re: ZRX Front End Replacement
« Reply #79 on: June 19, 2012, 03:52:50 pm »
thank you guys for the input.  As Willy noted, I had started another thread on this so that it might be easier to find by someone in the future instead of in the midst of a thread about a ZRX upgrade.  I'm going to post your input there for future reference if you don't mind.

thanks for the help!