Removing and Replacing a front fork stud

1977 KZ1000

I have a 77 and a 78 Kz1000. I am transferring my favorite parts to the 78 and creating a quasi show bike. The 77 has Z1R front fork down tubes and the lower portion is chromed. We all know how hard it is to keep the alum forks clean and get them the shine. Not a problem with these forks! I want to get them over to the 78. The problem is one of the studs has only a few good threads making it in my opinion unsafe. It needs to be replaced.

I know the trick to using two nuts together to back the stud out but these are steel in aluminum and I am afraid they are really stuck and I may snap it off. Then I would be in a world of hurt.

Questions:

1. Anyone done this before?
2. Are there any tricks to ensure success? (heat?)
3. Where can I get a replacement stud? What size are they? My experience with these type parts is the threads are different from modern so you have to get OEM or OEM direct replacement studs and nuts. Don't know why that is.
4. can any verify if Maybe the exhaust studs are the same size?

Any other info and opinions are always welcome.

Dave

Pair of vise grips on non threaded part of stud,reinstall with blue lock tite

If it was mine I would simply soak the old studs for 2 or 3 days with Kroil then remove them. I wouldn't be trying to replace them with exhaust studs or any other odd parts. I would just buy the correct fork studs and replace them. They are still available from Kawasaki so any dealer can order them for you. Ed

Could first soak for a few days in a 50-50 mix of ATF and acetone.

Heat with propane torch before attempting to remove the stud.

Thinking the fork studs are slightly longer than exhaust studs.

Would check with Z1 Enterprises for the fork studs.

Lots of good info on kawasaki.com, including parts diagrams, part names, part numbers, models sharing same part, availability, etc., and often includes sizes of various fasteners such as studs. Here's a link for help with navigating the site and finding information.
kzrider.com/index.php?option=com_kunena&...w&catid=13&id=376734

Good Fortune!

Getting the old one out with messing up the exposed threads won't matter. When your ready to put the new ones in, the double nut technique works great.
ACE Hardware, NAPA, etc will have studs in stock.

Patton, Is ATF = Automatic Transmission Fluid?? Never heard of using that. Dave

Knowmad wrote: Patton, Is ATF = Automatic Transmission Fluid?? Never heard of using that. Dave

Yes.

There was some testing reported in an earlier KZr thread which compared the penetration ability among several products such as PBBlaster, Kroil, Liquid Wrench, et al.

One "winner" in the competition was a 50-50 mixture of automatic transmission fluid and acetone, which was also the least expensive. And has been successfully used and reported by KZr members.

Could partially fill two cans with the mixture, and immerse stud end of the forks overnight or longer.

Heat with a propane torch immediately before attempting to twist loose should help release the thread grip in two ways. Any red loc-tite will loosen; and the aluminum female threads will expand more than the steel stud threads.

Good Fortune!