fork tube removal//help needed
- SPARKY47
-
- Offline
- User
- 1980 KZ500 B2
- Posts: 415
- Thanks: 5
Re: fork tube removal//help needed
17 Jul 2011 16:55
Crack it loose assembled.Spring pressure holds it all together.
Then tear it down.
Then tear it down.
1980 KZ500 B2
Location: Middle England[/b
Location: Middle England[/b
Please Log in or Create an account to join the conversation.
- andy9802gt
-
- Offline
- User
- If it tastes that good, eat it yourself.
- Posts: 704
- Thanks: 18
Re: fork tube removal//help needed
17 Jul 2011 18:51SPARKY47 wrote: Crack it loose assembled.Spring pressure holds it all together.
Then tear it down.
That's what I'm saying, leave the spring in and compress the fork it will hold it.
'78 KZ1075 LTD
stage 1 head by Larry Cavanaugh
race built crank by John Pearson
Mikuni rs34's
k410 cams
back cut tranny
8" over D&G swinger
proving once again that age and treachery is better than youth and enthusiasm
stage 1 head by Larry Cavanaugh
race built crank by John Pearson
Mikuni rs34's
k410 cams
back cut tranny
8" over D&G swinger
proving once again that age and treachery is better than youth and enthusiasm
Please Log in or Create an account to join the conversation.
- MkII
-
Topic Author
- Offline
- User
- Posts: 111
- Thanks: 1
Re: fork tube removal//help needed
20 Jul 2011 00:03
update. mission accomplished. had to fab a tool to 'hold' the piston by wedging the piston to the side and pinch it against the tube wall.
I hoped the technique of compressing the fork while assembled would do it, installed the forks and axle and via straps compressed the forks completely. It did give some resistance but still allowed the piston to rotate. no luck.
I hoped the technique of compressing the fork while assembled would do it, installed the forks and axle and via straps compressed the forks completely. It did give some resistance but still allowed the piston to rotate. no luck.
1977A1 current project: 1075, Web cams, VM29's Cavanaugh massaged head, Z1 crank
1979A3A Parked in 1986 left in shed
Phx,Az
1979A3A Parked in 1986 left in shed
Phx,Az
Please Log in or Create an account to join the conversation.
- Kapahulu
-
- Offline
- User
- Posts: 568
- Thanks: 44
Re: fork tube removal//help needed
22 Jul 2011 22:19
I am too sleepy to re-write the info in this post so check this link out:
www.kz-1000.net/forkdamper
1978 KZ1000, 1976 KZ900, 1975 H2, 1973 H1, 1973 H2, 1978 RD400, 1977 RD400, 1974 RD350
2strokeworld.com
2strokeworld.com
Please Log in or Create an account to join the conversation.
- 650ed
-
- Offline
- User
- Posts: 15343
- Thanks: 2829
Re: fork tube removal//help needed
22 Jul 2011 22:31
That will work great on fork cylinders with the hex indentation. Some of them (like mine) just have a round hole (see pic in my previous posting), and believe it or not the Kawasaki special tool is a nasty looking reamer that you jam down into the hole and it cuts into the fork cylinder to hold it. I substituted a rubber vacuum plug to prevent damage to the fork cylinder hole. I don't know why Kawasaki didn't use the indented hex on all of them; it really is a better design than the round hole. Ed
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
Please Log in or Create an account to join the conversation.
- MkII
-
Topic Author
- Offline
- User
- Posts: 111
- Thanks: 1
Re: fork tube removal//help needed
23 Jul 2011 00:19
I'm doing the MKII forks also and they have the 'round' damper as shown inthe pic above, I'll try these ideas suggested in building the tool for these forks.
1977A1 current project: 1075, Web cams, VM29's Cavanaugh massaged head, Z1 crank
1979A3A Parked in 1986 left in shed
Phx,Az
1979A3A Parked in 1986 left in shed
Phx,Az
Please Log in or Create an account to join the conversation.
- riverroad
-
- Offline
- User
- 1980 1000LTD B4
- Posts: 850
- Thanks: 7
Re: fork tube removal//help needed
24 Jul 2011 10:33
My 1980 fork had the 17mm hex socket in the piston and I made a tool for it, which woked great. But then I had to take apart a '78 fork tube and discovered the round hole piston top. So I had to resort to the tapered square broom handle. It worked great! I was surprised. I thought surely the oil in there would just make it slip, but no, I hammered it in and it wedged in there and held like a champ. Almost too well in fact. Had a helluva time getting it out of the piston. Just taper the broom handle so that the very end of the square is about 3/8" across, and the taper is about two inches long.
Please Log in or Create an account to join the conversation.
- 650ed
-
- Offline
- User
- Posts: 15343
- Thanks: 2829
Re: fork tube removal//help needed
24 Jul 2011 19:50riverroad wrote: My 1980 fork had the 17mm hex socket in the piston and I made a tool for it, which woked great. But then I had to take apart a '78 fork tube and discovered the round hole piston top. So I had to resort to the tapered square broom handle. It worked great! I was surprised. I thought surely the oil in there would just make it slip, but no, I hammered it in and it wedged in there and held like a champ. Almost too well in fact. Had a helluva time getting it out of the piston. Just taper the broom handle so that the very end of the square is about 3/8" across, and the taper is about two inches long.
I had considered the broomstick method, but I was too afraid of what I would face if the wood broke off in the hole (I know, I'm chicken!) That's when I decided to make a tool that couldn't break. Took about 20 minutes not counting the ride to Home Depot. Ed
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
Please Log in or Create an account to join the conversation.