Forks on Zong

[Pliskin]

http://img593.imageshack.us/img593/1035/img5372g.jpg (http://imageshack.us/photo/my-images/593/img5372g.jpg/)

First time I noticed oil on top of fork cap i thought it was from tree sap. I cleaned it and then few few days ago i saw oil again, so i
knew it was from forks. The oil has dried up and probably some has gone back in not visible in the picture. I am assuming it's o-ring
that I will need to replace. Would anyone know, which o-ring is compatible?

Spud has given compatibility list, but would o-ring be the same, as he was changing fork oil seals and dust wipers but not o-ring?

Honda bikes that Spud listed.
CR-80R (96-02)
CR-85R (03-07)

CRF-150R (07-09)

CRF-150RB (07-09)
NX-250 (88-90)
XR-250R (81-82)

Thank you.

[SpudRider]

The Zong employs the same forks as most of the Hondoid Chinese motorcycles, Pliskin. ;) Therefore, if you can find an O-ring for one of the Hondoid forks, it will undoubtedly fit your Zong.

Also, you can remove the O-ring, and take it to a Caterpillar Tractor repair shop. They can measure the O-ring, and can usually find a replacement for just about any O-ring you can imagine. ;)

I will check my records and see if I can find information on the O-ring which fits the fork caps. ;) However, I doubt the O-ring from any of the Honda forks you mentioned will fit your Zong's Chinese fork. :(

Spud :)

[Pliskin]

Also, you can remove the O-ring, and take it to a Caterpillar Tractor repair shop. They can measure the O-ring, and can usually find a replacement for just about any O-ring you can imagine. :wink:
Thank you Spud, :) that's what I was thinking of doing. I'll start my hunt tomorrow.

[Weldangrind]

I have an assorted o-ring kit that I picked up for cheap, and it has saved me several times. Can you buy something like that locally?

[SpudRider]

I'm not so sure your forks are leaking oil, Pliskin. I think you would see a much bigger mess if the O-ring in the fork cap had failed. ;) You would also see oil around the circumference of the oil cap.

Spud :)

[FastDoc]

I have an assorted o-ring kit that I picked up for cheap, and it has saved me several times. Can you buy something like that locally?

+1. I have a few kits from HF that I use for non-critical situations.

[Pliskin]

http://img37.imageshack.us/img37/4703/img5373r.jpg (http://imageshack.us/photo/my-images/37/img5373r.jpg/)

Can you buy something like that locally?
I am sure you can, but never looked into it.

You would also see oil around the circumference of the oil cap.
You are scaring me a little now Spud. :? I went for a short ride as i needed to change engine oil and after a short ride i could see oil coming out.
Took the picture as well. My guess is o-ring, what do you think it could be if not o-ring?

Need to buy a wrench of some sort first. The fork cap according to my measurement is 22mm.

[SpudRider]

Egads! 8O I now believe the O-ring is leaking. ;)

Zonshen does not list a part number for the fork O-rings. If I were you, I would remove the O-ring and take it to a shop, such as Caterpillar, which can measure it for you. Once you know the size, you can surely find a replacement. ;) Now is a good time to change your fork oil, as detailed in the following thread. :)

http://chinariders.net/modules.php?name=Forums&file=viewtopic&p=137744&sid=d1ee7461b82538108dc12af70b785e6f#137744

Spud :)

[katoranger]

I think I can see a bit of a pinched o-ring in the picture.

[zingshoen]

nothin a bit of permatex silicon glue won t fix :D

but a set of o rings should be easy to find. try supercheap or autobarn. i bought a set from the vietnamese 2 dollar shop, and they are good little o-rings :wink:

[Weldangrind]

I think I can see a bit of a pinched o-ring in the picture.

That's what I thought as well. That's an amazing photo.

[FastDoc]

Bike is safe to ride in the meantime.

[SpudRider]

I think I can see a bit of a pinched o-ring in the picture.
Good eyes, Allen! 8O

Spud :)

[SpudRider]

I think I can see a bit of a pinched o-ring in the picture.

That's what I thought as well. That's an amazing photo.
You've got a very good camera, Pliskin! :D That is a great photograph, indeed. :)

Spud :)

[SpudRider]

http://img37.imageshack.us/img37/4703/img5373r.jpg (http://imageshack.us/photo/my-images/37/img5373r.jpg/)

...Need to buy a wrench of some sort first. The fork cap according to my measurement is 22mm.
That fork is also sitting too low in the upper triple clamp, Pliskin. ;) Either the fork was installed too low at the factory, and/or or the pinch bolts in the triple tree are too loose. ;)

I agree, it's safe to ride the bike for a while. However, as with most Chinese forks, your Zongshen forks don't contain much fork oil. :roll: Therefore, I suggest you service the forks, re-install them a little higher in the triple tree, and replace the damaged O-ring. You can temporarily repair the O-ring with some black RTV, as Zingshoen suggested. If you measure the O-ring after it is removed, you should be able to find a replacement, and install it later, with the forks in place. Just loosen the top pinch bolts in the triple tree before you either tighten, or loosen the fork cap.

You don't need a 22mm socket for the fork cap. The socket is nice, but an adjustable crescent wrench will work just as well. ;) That's what I used when I serviced the forks on my Zong. :)

Spud :)

[katoranger]

I think I can see a bit of a pinched o-ring in the picture.
Good eyes, Allen! 8O

Spud :)

I haven't hit 40 yet.

[Pliskin]

I think I can see a bit of a pinched o-ring in the picture.It does look like it, but it's only an illusion from oil. If you see the first picture it's not there.

nothin a bit of permatex silicon glue won t fix :D That's a good tip. But i will check today for o-rings as you suggested at Supercheap.

You've got a very good camera, Pliskin! :D That is a great photograph, indeed. :) Thank you Spud. :) It's Cannon ixus 220hs. It has an option of doing micromode.

That fork is also sitting too low in the upper triple clamp, Pliskin. :wink: Either the fork was installed too low at the factory, and/or or the pinch bolts in the triple tree are too loose. :wink: You know i was thinking that too. It just looks low.

Therefore, I suggest you service the forks, re-install them a little higher in the triple tree, and replace the damaged O-ring.Spud how higher are your forks, just from visually looking at your Zong?

The socket is nice, but an adjustable crescent wrench will work just as well. :wink:I have adjustable crescent wrench but was scared of using it, as it tends to slip and damage the bolt. I tried with my new box wrench and was able to unscrew caps slightly. I was surprised how easy I was able to undo the fork caps. :? I remember how you mentioned they used lock-tight. Will keep you updated.

[SpudRider]

...Spud how higher are your forks, just from visually looking at your Zong?...
The top of the fork tube (not the fork cap) should be about 1mm above the top of the triple tree. Your fork tube is located below the top of the triple tree. :?

...I have adjustable crescent wrench but was scared of using it, as it tends to slip and damage the bolt. I tried with my new box wrench and was able to unscrew caps slightly. I was surprised how easy I was able to undo the fork caps. :? I remember how you mentioned they used lock-tight. Will keep you updated.
The fork cap unscrews easily from the fork tube. The damper rod is screwed into the fork cap with loctite. ;)

Spud :)

[zingshoen]

supercheap and autobarn can vary a bit from store to store, autobarn in ipswich is quite good, most stuff on the shelves and guys with know-how.

the silicon glue i recommend is permatex 66B, keep it in the fridge once opened.

[Pliskin]

http://img402.imageshack.us/img402/392/img5437rr.jpg (http://imageshack.us/photo/my-images/402/img5437rr.jpg/)
I raised the front wheel and unscrewed it up to here and no matter how much i was turning it, it wouldn't come off. Wasn't sure what
I was doing wrong. Then I tried with lowering the wheel.

http://img17.imageshack.us/img17/3906/img5438r.jpg (http://imageshack.us/photo/my-images/17/img5438r.jpg/)
As soon as I did that it popped right up.

http://img23.imageshack.us/img23/1811/img5447j.jpg (http://imageshack.us/photo/my-images/23/img5447j.jpg/)
Once fork cap removed. Indeed Spud, that's where i found lock-tight inside the thread on fork cap.

http://img703.imageshack.us/img703/1431/img5444wz.jpg (http://imageshack.us/photo/my-images/703/img5444wz.jpg/)
I have a question. If i remove this screw (which is located on bottom of fork) can i drain the oil this way. Then just pour oil on top
without removing forks :?:

I found o-ring at local all bearings shop. He did the measurement i took the fork cap as well. But when i got home i saw that new o-ring
is a bit thinner than old one. Will test it tomorrow and let you know.

The top of the fork tube (not the fork cap) should be about 1mm above the top of the triple tree. Your fork tube is located below the top of the triple tree. :?
Thank you Spud for letting me know. :) I guess I will have to adjust them, no matter how much I am trying to avoid removing forks. :lol:

the silicon glue i recommend is permatex 66B, keep it in the fridge once opened.Thank you Zingshoen.

[Weldangrind]

A thin film of grease on the o-ring might help. It will prevent the o-ring from tearing, and it will help it to seal.

[SpudRider]

...I have a question. If i remove this screw (which is located on bottom of fork) can i drain the oil this way. Then just pour oil on top
without removing forks :?:...

The top of the fork tube (not the fork cap) should be about 1mm above the top of the triple tree. Your fork tube is located below the top of the triple tree. :?
Thank you Spud for letting me know. :) I guess I will have to adjust them, no matter how much I am trying to avoid removing forks. :lol:...
Yes, you can drain the fork oil by removing those bolts. However, the job is much easier if you simply remove the forks. ;) I provide detailed, step-by-step instructions for servicing the Zong's forks in the following thread. ;)

http://chinariders.net/modules.php?name=Forums&file=viewtopic&p=137744&sid=d1ee7461b82538108dc12af70b785e6f#137744

Spud :)

[Pliskin]

Thanks Weld, that's great info. :)

Spud thank you for the link, and good to know that it can be done by removing the bolt i mentioned. :)

[zingshoen]

pliskin thanks for the industrial still life photos! your camera makes those threads look really good!

[SpudRider]

Thanks Weld, that's great info. :)

Spud thank you for the link, and good to know that it can be done by removing the bolt i mentioned. :)
Here's a link to a thread which describes how to change the fork oil without removing the forks.

http://www.mychinamoto.com/forums/showthread.php?1096-Changing-fork-oil-on-Qlink-QingQi-200

Personally, I would much rather remove the forks. ;) The job is easier with the forks removed, and one can do a much better job removing the old oil from the forks. Also, it's easier to measure the correct amount of new fork oil. In addition, you can inspect your forks thoroughly if you remove them. Indeed, with the Zongshen forks, you can even clean the oil seals and dust wipers without removing the oil seals from the forks! :D

Spud :)

[Pliskin]

Thanks Zingshoen, I am glad you like them. :D

Great link Spud I forgot about it, but remember seeing it before. I haven't decided about fork oil change yet. Thank you for all the help you offered and others of course. :D

[Pliskin]

I did 50km ride today and can report there was no oil leak. :D

[SpudRider]

That's great! :) I'm beginning to think your O-ring is fine. I believe you fixed the problem when you tightened the fork cap. ;)

I suspect Zongshen mounted the forks too low in the triple tree at the factory, and because of this they couldn't/didn't tighten the fork cap properly. :roll: I suggest you support the bike off the front wheel, and raise the forks slightly. You won't even need to remove the front wheel. ;) Merely loosen the pinch bolts, and slide the fork tubes up the triple tree, then tighten both fork caps. Finally, tighten the pinch bolts, lower the bike, and you are done. :)

However, you probably should change the fork oil fairly soon. It's not a difficult job. ;)

Spud :)

[Pliskin]

I'm beginning to think your O-ring is fine. I believe you fixed the problem when you tightened the fork cap. :wink:
It's possible, but I did notice that when i removed old o-ring that it wasn't holding shape.
Another thing I noticed it was placed in the middle (As can be seen from the above pic.) where the other one (non leaking) was pushed all the way up. That's how i place the new one too.

However, you probably should change the fork oil fairly soon. It's not a difficult job. :wink:
It will go on to do next, maintenance list. Thanks Spud, you are great encouragement. :)

[SpudRider]

Yes, the O-ring definitely belongs at the top of the fork cap. ;) I think you're in good shape now, Pliskin. :)

Spud :)