Replacing fork seals??

Hey all,

I'm stumped on this one. Getting the allen bolt out of the bottom of the fork leg seems to be a pain in the ass. I've replaced seals in the past with just loosening the bolt, but these forks are off a 76 KZ900. I know there is some kind of tool you can get for these, but shouldn't just work with an impact wrench? The bolt just keeps spinning in the stantion.
Any ideas or solutions would be greatly appreciated.

Thanks

You have to devise a mechanism to hold the inner fork still (while you unscrew the allen bolt). Sometimes just whacking the allen bolt with an impact wrench isn't enough. The inner fork mechanism just spins with the allen bolt. There are, in fact, special tools that will hold the inner mechanism steady but a number of members have used a wooden broom handle (with the end carved into a wedge-shape) jammed into the fork tube...this will slow the spinning while you use the impact wrench. I have used this technique and special tools...both work.

Here is a thread where we discussed how to make your own special tool for this:

tinyurl.com/6k74ho

Thanks for the info. I'll try the broomstick trick if not i'll fab something. Thanks again for the info.

Also attempt to remove the allen when your forks are still fully assembled. The spring pressure helps to hold the innerds from turning. Guys have had luck with the broomstick, but I've always doubted it working so never tried.

Tried removing it with the fork under load first. All it did was spin. I've never had this happen before. Every KZ fork I've worked on in the past, the bolt just spun out:S

Born Dead wrote:

Tried removing it with the fork under load first. All it did was spin. I've never had this happen before. Every KZ fork I've worked on in the past, the bolt just spun out:S

Hmmm...I've never had one that wasn't a complete pain to remove:)

This is difficult to explain but bear with me.
I read somewhere about a guy who used a well known principle for this pita.
You know on a bicycle, the bar which is at right angles to the handlebars goes down into the [headstock?] and its got this offset thingy on the end of it, as you tighten it one part moves sideways and locks the thing in position.
Anyone have the faintest idea what I'm rambling on about here?:blink: :woohoo:
Food burning:angry:
Anyway, he used this thing to grab the bit that spins to hold it.

Mcdroid wrote:

Born Dead wrote:

Tried removing it with the fork under load first. All it did was spin. I've never had this happen before. Every KZ fork I've worked on in the past, the bolt just spun out:S

Hmmm...I've never had one that wasn't a complete pain to remove:)

Well, believe it or not, I have 4 set's of 900 forks. I had 2 set's with the chrome rusted right off of them but the bottoms were still good. So I just made up a set of fork with good tubes and bottoms. Anyhow my story is all these were painless, but this recent set I got, are not as easy to service... Tonight will be the test.

SPARKY47 wrote:

This is difficult to explain but bear with me.
I read somewhere about a guy who used a well known principle for this pita.
You know on a bicycle, the bar which is at right angles to the handlebars goes down into the [headstock?] and its got this offset thingy on the end of it, as you tighten it one part moves sideways and locks the thing in position.
Anyone have the faintest idea what I'm rambling on about here?:blink: :woohoo:
Food burning:angry:
Anyway, he used this thing to grab the bit that spins to hold it.

I don't quite follow.....but I hope your meal was good...

I actually understand what youre talking about but every one Ive ever done came out with an impact wrench. Maybe try one of those inpact drivers that you hit with a hammer

Born Dead, food good, charcoal stimulating:P
Piccy alert...
The wedge is the part that matters,