my 650csr's transformation to the "RAT RACER"

Do an internet search for jarlef z650. The Files section has a manual for the 81 650-CSR.

A baby bottle is a handy measuring device.

martin_csr wrote: Do an internet search for jarlef z650. The Files section has a manual for the 81 650-CSR.

A baby bottle is a handy measuring device.

Hays trust me I have a baby bottle those things are awesome in the garage
Thanks for the help as always

There is no "exact amount" in terms of volume. The exact amount is adjusted by measuring from the top of the fork tube to the top of the fluid level using a rod or dowel. This is done with the springs in place and with the front wheel off the ground and the fork fully extended. After filing to the correct level you ride the bike and then check / adjust as necessary. The Kawasaki manuals do give a number of CC's, but this is just an estimate, that's why they also give the correct measurement in mm and describe the process. If you have the Kawasaki Service Manual, or if someone on this site has it for your exact model, the mm measurement is in there. Ed

For a complete rebuild, pour in the required amount in each fork, then you could do the dipstick check as outlined in the manual. Mine were very close, so I didn't bother adjusting the fluid level.

650ed wrote: There is no "exact amount" in terms of volume. The exact amount is adjusted by measuring from the top of the fork tube to the top of the fluid level using a rod or dowel. This is done with the springs in place and with the front wheel off the ground and the fork fully extended. Ed

This seems kinda odd to me. My fork oil process has always been springs removed, completely compressed and fill with oil to 6" from top. This is per Davey Durelle at www.durelleracing.com He has won a race or two in his time, and seems to know of what he speaks :dry:

slayer61 wrote:

650ed wrote: There is no "exact amount" in terms of volume. The exact amount is adjusted by measuring from the top of the fork tube to the top of the fluid level using a rod or dowel. This is done with the springs in place and with the front wheel off the ground and the fork fully extended. Ed

This seems kinda odd to me. My fork oil process has always been springs removed, completely compressed and fill with oil to 6" from top. This is per Davey Durelle at www.durelleracing.com He has won a race or two in his time, and seems to know of what he speaks :dry:

I have always used the instructions in the Kawasaki Service Manual with great success. I'm sure the guys who wrote the manual are familiar with my specific model. Ed

The factory manual for the 81 650 has the fork info (see jarlef reply above). The info is different than the earlier 650s. There's a table on page 2-21 which shows the amount of fork oil to add & how to check the oil level - do so w the engine blocked to raise the front wheel off the garage floor & springs removed.

The following link includes a free down-loadable factory service manual for 1981 KZ650 H1, F2 and D4.

jarlef.no/Kawasaki/Series/Z/650/z650files.htm

Good Fortune!

Good Fortune!

Would suggest remeasuring the level after drying and replacing the springs, and making a note of the level with springs inside, so that future level checks may be conducted without needing to remove the springs.

Good Fortune!

Different models have a different methods. The 550's are measured with no springs, and fully extended.

Follow the FSM for your exact bike only.

hey guys thanks for all the help
got the downloadable version of the manual from jarlef
forks are back together and fully rebuilt...had to replace the top caps as well seals were dry and wouldnt hold any pressure
pictures up tommorow
the bike is finally RIDEABLE!!!!!!!!! woooo
next is the "cafe racer" part of the build
but in the mean time im going to enjoy the nice weather central california has been blessed with some nice country rides