83 KZ 440 LTD - Rebuilding the front forks

I have to change the seals in the front forks and wonder if there is a good thread someone can paste to this request on this repair. is there a heavier oil i can use for a little stiffer ride up front? how hard is this process? Any tips on this?

im just venturing a guess here after looking at the parts diagram. I have never rebuilt any 440 forks, but they look VERY similar to kz1000/650 forks. So, yes they should be relatively easy to rebuild if you are mechanically inclined. If you have searched the site and haven't found anything i would acquire a factory service manual or similar. Unfortunately the KZ440 is not very popular on this forum so there is not as much info here. I thought there was a KZ twin forum but i cant seem to find it.

here is a link to a FSM for 80-82 KZ440s. not sure how much overlaps.
www.kz400.com/Workshop%20manual%20bilder...Service%20Manual.pdf

Anyhoo when you get into it, the bottom allen bolt can be a bit tough to get loose. the trick is to get it out is to whittle a broom handle into a square point, before you jam it down the stanchion tube into the damper rod shoot some brake cleaner down there to remove the fork oil. Tap it lightly in and you'll get much better purchase and should be able to get the bolt out. Or if you have a impact driver you can use that. Use a torque wrench when reassembling. I would use the recommended fork oil and see how a rebuilt fork rides before switching to anything heavier. They were designed with a specific oil weight in mind.

Thank you for the information ad the manual. That helps so much

Leave the forks bolted in the triple clamps when you attempt to remove the allen head bolt. After removal of that bolt
compress the top cap against the fork spring and remove the snap ring. There are no threads on the 400/440 top plug.
Those are really the only really trouble areas, everything else is ea.

I already had the forks out of the triple clamps. I unbolted the allen bolt at bottom and drained the oil out then removed the snap washer and the bottom fork slid off. All cleaned up and waiting on the seal and new dust covers to come in. Those items look pretty simple to put back together correctly but then what? What is the process for filling back up with oil, what type and how much? how do I know when full? And what is the air stem at the top of the fork for? Is that supposed to be filled to a certain pressure? help please. first time I have messed with forks so sorry if these are amateur questions.

also rebuilt front disc brakes, waiting on new brake pads front and rear, new wheel bearings front and rear as well as new neck/steering bearings on the way, then onto the carbs. I have another thread asking about jet sizes but not as good of response as this one. Thanks for your help on the forks.

150cc of 5w20

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Thank you sir....i assume that is for each shock and where do I fill them at? And what is the thing at the top of the shock under the rubber cap that looks like a valve stem for?

EastCoast wrote: Thank you sir....i assume that is for each shock and where do I fill them at? And what is the thing at the top of the shock under the rubber cap that looks like a valve stem for?

That is the forks. You fill them thru the top, then reinstall the cap. As for the 'valve stem ', I need a pic.


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OK well from what I read about the forks in the manual, on here and the you tube videos, I am wondering if these are the standard forks that came on the 83 kz 440 a1. I have attached a few pics for reference, any advice would be helpful. I am only replacing the seals and have to refill with new oil. Do I fill through the valve or take that out and fill? Or am I supposed to do something else and fill with air to a certain pressure? I am a little confused here.
Guess I dont know how to post a pic either.

OK I resized photo so we will see if it works now. Attached this time I hope.

EastCoast wrote: OK well from what I read about the forks in the manual, on here and the you tube videos, I am wondering if these are the standard forks that came on the 83 kz 440 a1. I have attached a few pics for reference, any advice would be helpful. I am only replacing the seals and have to refill with new oil. Do I fill through the valve or take that out and fill? Or am I supposed to do something else and fill with air to a certain pressure? I am a little confused here.
Guess I dont know how to post a pic either.

That valve is not stock, somebody has added it. You need to
compress that plug down ,remove the snap ring ,
clean the inside. Then add the fork oil and reinstall the plug
and snap ring. The purpose of that valve was to add
air to the forks like old school air shocks on cars of the same
tie period. If you think you are heavy enough to
need to add air to the forks, 1) install heavier springs 2) get a bigger bike.

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I am only 200 and haven't ridden it yet to know if I would need or want more stiffness but assume not. I was mainly curious due to it not looking like the pictures in manual or online. So the must have just tapped the plug up top in order to add air for this reason or could these top tubes be from another bike with the 440 bottoms on it? Is it safe that way if I don't add air and just do as you suggested and just clean, add oil and reassemble? Also, does that plug just push down to access the snap ring for removal or is there a method to it?