TOPIC:

Attempting to replace the fork seals on my 1978 KZ 1000 LTD. Have the forks removed from the bike and nearly disassembled but I have hit a snag. Can't get the hex head bolt, located at the axle area, removed from the outer tube.

I don't have the special Kawasaki tool and a piece of wood isn't holding the inner tube.

Suggestions?

Do you have an air compressor and an impact gun? If so have a helper, or maybe you can, try to pull the inner tube from the outer tube. Next get your impact gun and zap the bolt. It should come out. I've did a couple set of forks this way and always seems to work. Good luck!

Later, Doug

special tool eh... make one like i did. Get a 19mm nut or 1/4 bolt weld it to a rod and bam theres your special tool, works really good and the bolt should come out easy.

The bad news is, it took me going to someone with the airtool to loosen the bolt in the bottom of the fork. Hit it w/about 100 psi and it should loosen it. After that, I used a 3' section of 3/8" dowel with duct tape wrapped around the tip which I then jammed into the inner fork holder to hold it steady...then all came apart with hand tools.

Ah, the joy of working on older machinery. I don't have this trouble with my Spitfire racer.

Thanks for the suggestions.

Yea you need air tools or get one of the neat rechargable battery powered impact tools. Get the most powerful you can afford. It helps when removing the allen screw to have the fork cap and spring all still assembled as this puts spring pressure to help keep the inside from spinning.