Fork hex bolt size and more?

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13 Nov 2009 16:51 - 13 Nov 2009 16:52 #333501 by polkat
Fork hex bolt size and more? was created by polkat
Disassembling my KZ750H forks. What size is the hex for the bottom bolt? And when making a tool to hold the piston inside, what size bolt head is used?
Much thanks!
Last edit: 13 Nov 2009 16:52 by polkat.

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13 Nov 2009 18:08 #333520 by JMKZHI
Replied by JMKZHI on topic Fork hex bolt size and more?
8mm allen wrench. The head of the inner cylinder is 19mm (~3/4"); a 1/2" bolt should have a 3/4" head.
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14 Nov 2009 07:27 #333603 by RonKZ650
Replied by RonKZ650 on topic Fork hex bolt size and more?
If you don't have a 8mm, a 5/16" allen is the same. Use air tools and don't worry about the hold tool. They used different dampers in different models. I wouldn't bet on the 1/2" bolt being correct in every model. Use air tools and it doesn't matter.
321,000 miles on KZ's that I can remember. Not going to see any more.

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14 Nov 2009 07:44 #333607 by Link14
Replied by Link14 on topic Fork hex bolt size and more?
I'm going to have to try the air tool trick, 'cause a '76 kz900 fork doesn't have the inner cylinder head socket, and I'm just spinning the hex nut with an electric impact wrench.

I can confirm though that if polkat's forks are from a 82 750-H, then the tools that KMKZHI will work fine.

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14 Nov 2009 11:08 #333626 by JMKZHI
Replied by JMKZHI on topic Fork hex bolt size and more?
I just disassembled a fork leg from an 82 750H-Ltd-4, using a 1/2" left-hand-threaded bolt w a 3/4" socket & a couple of ratchet extensions. The inner cylinder (damper rod) appears to be the same as the 81 CSR's.
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14 Nov 2009 13:03 #333653 by polkat
Replied by polkat on topic Fork hex bolt size and more?
Thanks guys! Are there any seals or O rings on the damper rod itself that I should also change out?

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14 Nov 2009 13:11 #333654 by JMKZHI
Replied by JMKZHI on topic Fork hex bolt size and more?
No. The damper rod has a plastic sleeve of some sort on it, but I don't believe there's a replacement part out there. If you haven't purchased new seals yet, get genuine Kawasaki or K&L - both are made in Japan. Other brands are made in elsewhere (Taiwan, China, etc).

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14 Nov 2009 15:24 #333672 by polkat
Replied by polkat on topic Fork hex bolt size and more?
So this plastic sleve (I'm guessing the piston ring) generally stays reusable?

I already ordered the seals from our local all brands motorcycle shop. I don't know if they are Kawasaki or K&L (I was too stupid to ask) but they cost $29 for two, so I'm hoping they are good.

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