Fork Rebuild

I have my forks apart to to replace the badly leaking fork seals. Is there anything else I should be doing while I am at it? I cleaned all the internals and checked for nicks and scratches in the chrome (there was none). Should I replace the bushings? How would I tell if they are worn. They are dark grey in color with no gouges or nicks. Is there anything else I should be doing? Oh and I had planned to use 15w oil. I am over 200lbs and a careful (read: slow) rider.
Thanks,
Jim
Oh, and should I be replacing the brake pads since the fork oil got on the disc?

Brake Kleen will get any oil off the pads or discs, but be sure to use it in a well ventilated area.

What year/model Kawasaki is it?

If it is a 83-85 GPz, there is a write up in one of the GPz750 FAQs (Google) about rebuilding the forks and repairing the bushings. If it's an earlier model then I don't think it has separate bushings.

Its an '82. It looks like the bushings can be removed and replaced. At least they look like the ones I have replaced on my dirt bikes. I just don't know whether or not they need to be replaced.

Look for wear on one side, if it's pretty obvious, replace it.

OK Got both forks apart.
There are two bushings on each fork. One at the end of the stanchion and one at the top of the fork lower. However, the manuals and online parts breakdown only show the one at the top of the lower fork leg just below the seal. The one at the end of the stanchion on the right forkleg is worn on one side and I would feel better if I could replace it. Are these non-replaceable?
TIA,

Do you have photos of the assemblies and bushings? I tried to look up you bike on Kawasaki's site but either their database is crashed or they have removed the database from public view so I can't be sure where you are indicating.

OK Here is the assembly. From left to right: The stanchion with the bushing on the end. The bushing that goes into the lower fork tube and the lower fork tube itself.



And here is a close-up of the two bushings in question:


It's hard to see but the one on the left that goes on the end of the stanchion is worn on one side. The catalog at Babbits as well as my manual only show one bushing (the smaller one) for the KZ750R1. Strange.

Since you have them apart you should replace all the stuff.

Since you have them apart you should replace all the stuff.

Yeah, problem being the larger bushing does not show on the parts diagrams.

I could only get one of the two bushings from Kaw, I think it was the smaller one. They aren't cheap either for what you're getting.

If you can't replace one of them then just clean them but don't try to polish them up. It's the best you can do and it should be alright. Most never do that they just through another set of seals in and ride it until the leak comes back like before. The condition of you inner fork tube The chrome one you see when looking at the bike is more important as to it being smooth and free of rust, nicks and grooves. Be sure you didn't gouge the cavity in the lower fork tube where the seal sits from removing the old one too. That's about it besides putting back together in the right order on the damper assembly.

I recommend using the volume fill and the fluid height check per the book too, just by volume isn't as accurate.

Thanks KZ_Rage,
I figured I would have to measure the fork oil height. been there/done that on my Hondas and Yamahas.
I went to the Kawi dealer and they all scratched their heads too. The larger one should be replaceable but unfortunately it looks like it is not. They didn't have the copper sealing washers I needed either. Oh, and they wanted to charge me $45 to change a tire off the bike. In the future I'll be steering clear of that place. Shame since I bought two NEW motorcycles from them.

Son of a...

Guess what I'm up against! That's right, my lower bushings are worn, and there's not a part number listed on buykawasaki.com!

Anybody have any ideas as to where to find a replacement? I figure we're all going to have to replace our lower bushings at some point if these old bikes are to stay on the road for the next couple hundred years, right?