fork oil change

bought some forks for my 82 kz550 ltd and they need to be filled with oil but i cant figure out how to do it. they are the air adjust type and my Clymers manual does not mention how to get the circle clip off the top plug for this type. the air valve is in the way of pushing the plug down with a screw driver and im afraid that if i push too hard on the sides of the plug it will bind or something. any suggestions?

May find some help, courtesy of these links provided by KZr Member loudhvx:

General
home.comcast.net/~loudgpz/GPZweb/index.html#home

Service manuals
home.comcast.net/~loudgpz/GPZweb/Mnls/Mnls.html


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pictures help

thanks patton that manual is great but it does not tell me how to remove the top plug either, it only says that i have to do it in order to change the oil. i believe the forks were off a 1980 550 ltd and i would upload pictures but i cant get it to work

Relieve the air pressure, then try to unscrew the air valves. If they seem stuck & the fork plugs spin, try compressing the forks, then try to unscrew them. I guess you could try using tie-down straps to compress the forks? -- >> Forks & front wheel still on bike.

After removing the air valves, you have to press down on the plugs, then remove the circlips. Some guys use a tool to compress the plugs, but I don't recall what they use & I couldn't find a topic. I think it was something from the auto parts store? In lieu of the tool, a extra pair of hands might come in handy.

Did Ya get it yet???? But martin is right. extra set of hands is the answer. used a ratchet extension and rag to push down on, while freind got the circlip. stronger person does the pushing.

got the ring clip thing out on one of the forks but the plug still wont come out. is it threaded or something?

anyone? this is really killing me

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May use diagrams at kawasaki.com to compare any differences between the '80 and '82 versions.

See link in my signature for help with finding parts diagrams and other information on kawasaki.com.

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There may be grunge & corrosion keeping the plugs from coming out. Or the old o-rings are impeding removal. I would spray in some Liquid Wrench penetrating lube.

Not sure how I would go about it. Maybe put a heavy cloth over the plugs, then apply downward pressure on the forks? Idea #2. Using a long bolt w the correct threads, install the bolt where the air valves go, then use that as a tool to twist & pull the plugs out?

The Haynes manual for the EN450 (454Ltd) has some good photos & I'm pretty sure the forks are similar to yours as it has the same fork plugs (Fork Spring Seats). Here's a 454Ltd how-to topic w photos. How To: Fork Seals

thanks guys. i was able to get the plugs out by threading a bolt in where the air valve goes and pulling on the bolt until they came out.