Instructions for ZX12R Front End Lowering Kit



Instructions for LK-1001 and LK-1003 Front End Lowering Kit

This instruction sheet is intended only as a guide for installation of the kit. For safety and proper performance, it is recommended that only experienced motorcycle mechanics perform this procedure.

Read through all of the steps of this instruction sheet before starting. It is important to be aware of the amount of fork oil removed so that it is refilled properly during re-assembly. Use a suitable thread lock for re-assembly as needed.

Kit Contents

(2) 12mm Washers

(2) 1-1/8” Long Spacers

(2) 3” Long Spacers

(1) M12x1.25 Nut

Procedure

Remove the forks from the bike.

For each of the forks, do the following:

1. Remove the lower seal bolt (10mm hex wrench) and brass seal using an impact wrench. (The inner fork assembly will spin if an impact wrench is not used.) When the bolt is removed, the fork oil will flow out of the hole, so place the end of the fork in a container to catch it. If you want to re-use the original fork oil, use a clean catch container. When refilling, you will need to top it off slightly for the loss of oil during disassembly. (If drained thoroughly, not more than an extra ounce). Use 10W-fork oil.

2. Unscrew the upper fork cap assembly (30mm socket) and pull the inner fork assembly out of the fork tubes. It will save a lot of cleanup if you drain as much of the fork oil as possible into the catch container at this time.

3. Remove the lower cartridge cover from the inner fork assembly. First, place the assembly in a vise at the aluminum slide just above the cover. Then, unscrew the cover with a pipe wrench. It is best not to jerk the wrench to break the cover loose, just apply even, steady pressure. (See illustration 1.)

4. Use a spring compressor to compress the upper spring far enough to expose the nut securing the upper fork cap. If you do not have a spring compressor available, one can be made using two 1-1/2” x ¼” x 5” long strips of steel, two 24” long 5/16 threaded rods, four 5/16 washers and six 5/16 nuts. (See illustrations 2 and 3.)

5. Remove the upper fork cap by backing the lock nut off (17mm wrench on the nut and a 30mm socket on the cap), then unscrewing the cap.

6. De-compress the upper spring and remove the spring compressor.

7. Use the M12x1.25 nut included in the kit with the upper fork cap lock nut to double-nut the main shaft for removal of the lower dampener assembly. Secure the lower dampener assembly in a vise and unscrew the main shaft from it using the double-nut. (See illustration 4.) When removing the dampener assembly, be careful not to lose the spring and needle valve inside the dampener assembly.

8. From the kit place one of the 12mm washers and one of the 1-1/8” spacers just below the lower (pre-load) spring and re-install the lower dampener assembly.

9. Remove the extra nut from the kit for use on the other fork. Compress the upper spring again to re-install the upper fork cap with the kit’s 3” spacer in place of the original 4-1/4” spacer. Be sure to put the end of the spacer that has been cut down slightly into the spring cup. When re-installing the upper fork cap, screw it down as far as it will go by hand, then tighten the lock nut against it.

10. Remove the spring compressor and re-install the lower cartridge cover.

11. Replace the inner fork assembly into the fork tubes.

12. Re-install the lower seal bolt and brass seal.

13. Holding the fork assembly upright, refill the fork oil then screw the cap assembly back into the upper fork tube. NOTE: To refill according to the service manual requires a Kawasaki fork spring compression tool. If the tool is not available, a good approximation would be to fill to 1” below the upper edge of the lower fork tube with the complete inner fork cartridge assembly in place but not compressed. The best method is to carefully measure the amount removed, then refill with that amount (provided there were not any problems with oil before disassembly).

Replace the forks on the bike. The kit will reduce the fork lengths by 1-1/4”. Additional lowering can be accomplished by re-installing the fork with the top extended above the upper triple clamp. DO NOT EXTEND IT MORE THAN 1-1/2” ABOVE THE TOP CLAMP. The fork tube diameters taper down beyond that point and therefore would not be secure in the pinch clamps. (See illustration 5.)

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