Fork Seals

Can anyone tell me if there is a manual out there for a 1982 KZ 750 M1 (CSR-Twin)? I've looked on the Clymer website and can't find one there. The kawasaki dealer said they could order an official kawasaki manual for twice the price MSRP of a clymer. Also......how difficult is a front fork job for a DIY'er? The local shop quoted me about 320 large. Any help would be appreciated.:huh:

godom72 wrote:

The local shop quoted me about 320 large.

$320,000????

:ohmy:

Wow. I'll fly out and do it for 50 large.

:side:

Here's a KZ750 manual. Not your exact model/yr, but maybe the forks are similar:

www.metrovationinc.com/kz750.pdf

Fork seals are a piece of cake. You may have to purchase or make the fork tool but that is pretty easy too. Just make sure you make a note of how everything comes apart. I like to lay my stuff out in order of disassembly.
HTH,
Jim

I bought a manual for my 1980 750E1 for 10 bucks on CD off E-Bay.

This is a good topic on changing fork seals. Just got mine from Z1 today.

kzrider.com/index.php?option=com_kunena&...ew&catid=5&id=211619

As Skyman suggested, $320 is a bit steep...but most independent bike shops (non-dealer) should tackle a fork rebuild for about US$150.00...you have to decide if you want to learn how to do it or have it done and not worry about it. I went the 'learn to do it' route because I have more than one bike:) The learning curve is steep and the trick is having or fabricating the correct 'special' tools. The job will be easier with the correct KHI shop manual in hand (eBay will be the source)

I wouldn't be surprised if your bike and my '82 kz750 ltd have similar forks. The hardest part for me was figuring out how to get them apart. From some ideas from the guys here, had a buddy of mine weld a 1/2 inch nut on to a 30 inch piece of steel rod (also welded a small T-handle on the end). This gives a 19 mm outside dimension which you need to fit into the inner tube socket. Then all you have to do is hit the 8 mm hex nut with an impact driver a couple of times and it's downhill from there.

Thanks to all for the help. I'm getting a list right now of all my coworkers that know a cycle mechanic that doesn't work in a dealership. Still undecided if I'm going to attempt this part of the restoration/conversion myself, or let a seasoned vet doer for me. Thanks again gents and happy riding.

del