Want to rebuild the forks on my 81 kz1000

Do I just need the seals for liek ten bucks or is there more to it?

How is your tool chest looking? There are special tools required...or some tools can be adapted/fabricated.

It's nice to have an impact wrench to spin off the allen nuts at the bottom of the forks, and also nice to have a fork seal driver. I know some have used things like pvc pipe sections to drive the seals but a dedicated tool sure makes it easier.

Probably half a day for everything (taking stuff apart, figuring out your way around, putting it back together) if you've never done it before, but then more like 90 minutes after that.

Oh, center stand makes it much easier to get weight off the front end too.

Good luck!

I'll just add to this thread...

My seals are looking a bit old and are up for replacement - has anybody had experience with pyramid seals? They seems pretty easy to come by.

Also, I have a 1985 kz250 - are the seals on all kz250's the same?

And is it worth getting dust boots?

To Irish Yobbo: I don't know where Pyramid parts are mfg, but I would only get Made in Japan fork seals. The Kawasaki dealer may have the correct stuff for your bike. The ones for the 83 250-W1 are listed as Active, but I do not know if they are the same as your 85 model. The earlier 250-D fork seals have a different part number.

Yes on the dust boots. I did a simple drop test w the fork springs removed & new seals installed: the tubes dropped more slowly w new dust boots installed, compared to the old ones.

Note: the 85 KZ250 was not sold in the US, so the parts diagrams at the various sites may not have specific info for your W model.

I bought BikeMaster "OEM" seals on eBay and they seem to be working great. $16.28 shipped.

I've been looking into the process for replacing the seals - it seems simple enough. Now my next question is, when should I replace my seals?

I was going to do it as the seal look old, and I figures that was a good enough indication. But I've heard some people say to only replace them if they leak. I'd rather err on the side of caution and replace them.

Are the seals a single seal, or is there a cover that is put over the top? I know of the dust covers (mine doesn't have them) but the lip of the recessed rubber (which I presumes was the seal) is cracking - but it still seems to seal. There isn't a 2-part seal or something, is there?