77 kz 1000 fork tube

hey all, need some help . im having a problem removing the allen bolt going into the bottom of the fork tube. it seems to be frozen. i can turn the bolt loose . but it will not come out from fork tube. iam rebuilding the forks. any suggestions will be very helpful. thanks.

There is a tool that holds the inside sleeve from turning.

What also works is a large "Easy Out" on a long extension. You must than use an impact wrench to tighten them because the "Easy Out" will not hold the inner sleeve for tightening.

use an impact to spin it out

You will have to do a search on this site on replacing fork seals and disassembling the forks. It has been well covered. Basically, as has been mentioned, you have to construct/make/borrow a tool to hold the inner fork tube while you remove the lower fork bolt. The manual demonstrates this rather well

Has anybody got a picture of a homemade constructed tool for this procedure...I would like to make one...is there threads on top of the cartridge that I could weld a Nut on a long bar...and if so...What size of thread is it?
After Searching other Threads....The "Broomstick" method - do I drill a Hole into the center of the stick in order to jam into top of cartridge and then turn Allen bolt on the Bottom?...:blink:

3\4" bolt with two nuts. Socket and long extensions works perfect.

Ironpan65...I'm assuming you are disassembling one of your Z1's? IIRC, the Z1 has a weird bolt on the inner fork cartridge. That bolt must be held still in order to spin out the bolt on the bottom of the fork leg. The inner bolt head is almost circular but with two parallel flat sides...if you have this situation, then go to Walmart and buy a 'Gator Grip' socket...locate a socket extension and use that and the new socket to hold that bolt steady while you turn out the outer bolt. This really works...it is only thing I use that silly socket for but it is worth every penny.

I always use a piece of wood. I just tap it down and then hit it with a impact wrench. Roy

Thanks for the pic Cuff.....
Yaaa....working on the 74....The Bike is a bit of a Frankenstein....thought maybe it had a newer style fork...(77?)

Top of the Cartridge looks Round when I look down inside....thought maybe there were threads on it(?)

Ok...I will try to find a Gator Grip Socket...and will pick up a stick also....

Thanks

The 3/4" bolt setup works on some 80s models, such as my 81 KZ650, because the head of the inner cylinder looks like a 12-pt socket (it's actually 19mm).

The bolt deal may not work on earlier models. A wooden dowel or rake handle w the end carved into a wedge or something might be the best/easiest thing to use. The special Kaw tool is in the shape of a pyramid - the ones I've seen anyway.

Factory tools, for reference ---

[Click on image to enlarge view.]



Good Fortune!