76 kz900 A4 Fork Oil

I guess I am confused on the amount of fork oil needed. The paperwork with the new springs looks like it is telling me I should add oil to within 5.5 inches of top of extended fork but the online manual says 16.5 inches from top of fork. I guess I am reading something wrong.

5.5" is way too much oil. With that much oil in there with the forks fully extended your forks would have nearly zero travel when you hit a bump. My KZ650 fork oil level is about 15 1/8" with forks fully extended and my front fork travel is 5.5" Ed

Just add by fluid measurement.

Assuming you're doing a rebuild, just add the specified amount. A baby bottle is a handy measuring device, as it has ccs or mls

The fluid CC measurement may be an ok way if you have completely rebuilt them and know all the old fluid is out the the innards are dry, but otherwise measuring from the top is preferred because there may be some old fluid remaining in the nooks and crannies, and one fork may have more than the other. Ed

Since I have already put oil in what should the measurement be.

1. From where?
2. Spring in or out.
3. Tube extended or compressed.

Wish I had done this right since it looks like I have to pull the fork tube out to get the top cap off. Thanks for your help.

Here's what the manual recommends:

Measure from the very top of the inner fork tube where the plug screws in.
Measure with the springs in.
Measure with the front wheel off the ground and the forks fully extended.

You should not need to pull the fork to remove the cap. However, you should loosen the top clamp bolts as this makes removing the plugs easier.

Ed

Just went to the shop and there does not seem any way to remove the fork cap without removing the fork tube from the bike. The handle bars overhang the caps about a 1/4 inch and the plug is too long to remove before it hits the bottom of the bars. Not sure if something else is wrong but I know these handlebars are the ones that came on the bike new. Not sure if the dealer changed something or not since I have never looked a any other kz900 a4 bikes. Thanks

There should be enough space (see pics below), but if not wouldn't it be a lot easier to loosen the handlbars than try to remove the forks? Ed

Handcannon wrote: Just went to the shop and there does not seem any way to remove the fork cap without removing the fork tube from the bike. The handle bars overhang the caps about a 1/4 inch and the plug is too long to remove before it hits the bottom of the bars. Not sure if something else is wrong but I know these handlebars are the ones that came on the bike new. Not sure if the dealer changed something or not since I have never looked a any other kz900 a4 bikes. Thanks

Would put a protective cover on the tank, and then remove the handlebar from its clamps, and set the handlebar on the tank.
Should provide ample access for unscrewing and removing the fork caps.

Good Fortune!

Yes It would be better to remove the bars but I still have the front tire off so it is not much of problem to take the fork tubes off. Because of some issues rebuilding them I am getting fast a removing and installing them at this time. On another note the new springs I am installing are longer than the stock ones and stick out of the fork tube about 3/4 of a inch. Guess it is ok just to force them down when I put the cap on? I may call and confirm this with Progressive Suspension tomorrow since I have some more time now.

In situations where the fork cap may be screwed in there very tight --

With fork tube removed, should exercise caution not to damage the tube when holding it in position to allow torquing the cap.

For instance, clamping the tube in a vise may damage the tube; whereas, leaving the tube in its normal clamped position, with the top clamp loosened, usually allows removing the cap without damaging the tube.

Good Fortune!