Forked for now

Venting my frustrations online because my co-workers are sick of hearing it

A week after my mechanic friend at the Kaw shop aired up the forks, the front end feels soft again to me on my 82 KZ440. Ran over to the auto parts store to get a nice digital gauge at lunch and the left fork is at 0psi, the right at 3psi. They were both filled to 7 a week ago. Borrowing a hand pump to take them back up to 7 tonight and see how fast the leak is.

Waiting for my Clymer's manual now, no idea how in-depth it will be on fork maintenance. Regardless, I've never torn a set of forks apart and wouldn't know where to start. I am eager to learn, just not sure I'm comfortable with front end work yet.

I'm not against the idea of new seals and possibly progressive springs. Just wondering how much $$ I will need for the project. The shop right now has 95 bikes in line for repairs so he doesn't even have time to talk at the moment.

Till then, I guess it's back to trying to shine up old aluminum, hehe.

Can anyone give me an idea of how skill/labor intensive the job would be?

Thanks,

Brian

Get the manual,what part of nebraska are ya in?

If you have not done so yet check out the following, IIRC you can download manuals for the 400/440 models there. There is also a bunch of great info on the site about the bikes.

www.kz400.com/index.html

Get a Manual, the Factory Manual is much better than the Clymers.
Here is the parts breakdown, the fork seals #92049 are held in by the retaining clip #92022, which is hidden when you look at it by the dust seal, #92093. The seals can be changed easily with out Fork disassembly, but the fork leg must be removed from the triple clamps. There are tools sold for driving the seal back in place, but a piece of PVC pipe works good, Lowes/ Home Depot, seals are like $15. You can Drain and refill the oil, easily also. There is specs for the oil viscosity and how much to re-fill. The best way is a oil level measurement, distance from the top of the tube. This is usually with the spring removed and the fork tube collapsed. If you want to do the oil change, loosen the top cap before removing from the triples, or do it when they are in place to hold them.

Be sure to check the fork air w the front wheel off the garage floor. Also, use a low pressure gauge, not a typical tire gauge.

Thanks for the replies.

Wireman - GI

gd4 - You're right, I had grabbed the service manual there previously

Motor Head - I had downloaded the service manual but I'm shaky on the instructions I see there. Appreciate the tips and part numbers. Still trying to wrap my head around how the cap at the top is put together and that clip that everyone complains about.

martin - I think you're right. It's probably not what most would consider a difficult job, but having never done it before, I do find it intimidating the first time. I really want to do it myself but...


My next plan is to put bit of air in (again, with the proper pump) and try to soap bubble it to see where the air is leaking. Would be nice if it was something as simple as the valve core in the schrader valve but I doubt I'm that lucky, hehe.

Again, THANKS TO ALL. You guys are a great help.

Ride it to louisville and Ill help ya work on it! :laugh:

I was just in Louisville for Warrior Dash! lol

Good times.

We have our moments! :woohoo:

Still no progress on forks. Considering just adding some oil to see if the seals are shot. The way they feel, there's no fluid exchange going on at all and I suspect they've been empty for quite awhile. Only concerned about leaking oil onto the brake, but will just watch diligently I suppose.

Really want to replace the seals, but my friend keeps reminding me 'how much money do you want to put into this bike?'. He's right, I know, and I'm already itching for something bigger. I'd like to do the seals both for a better ride now and the experience of learning how, but don't like spending money unnecessarily either.

Just venting, sitting at work, trying to get a list together of parts I'd need to estimate cost.

Well if you pull the forks off and order the seals from z1enterprises I can meet you on your side of lincoln and pick them up from you and have them rebuilt for you in a couple days as long as you buy the parts and mountain dew,or you could just fed ex them to me for same deal.

What 440 model came with air forks? Are they an aftermarket bit?