Fork top removal?
- Rustyhama
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Fork top removal?
25 Jun 2014 12:23
I need to check my fork oil level (among other things). The manual says 'remove the top plug and pull out the spring' but how do you get this thing out? Sorry if this is a dumb question...
Attachment IMG_20140626_065822.jpg not found
Hama
'82 KZ305-B1 Cafe Racer
'80 Z750E project
www.dotheton.com/forum/index.php?topic=59260.0
'82 KZ305-B1 Cafe Racer
'80 Z750E project
www.dotheton.com/forum/index.php?topic=59260.0
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- 650ed
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Re: Fork top removal?
25 Jun 2014 12:26 - 25 Jun 2014 12:27
I may be wrong, but it looks like you would depress it in a little and remove the circlip. Ed
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
Last edit: 25 Jun 2014 12:27 by 650ed.
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- Rustyhama
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Re: Fork top removal?
25 Jun 2014 12:32
That looks like the answer thanks. I can do use it down a few mm which exposes the circlip. Then I should be able to hook it out with a small screw driver. Thanks Ed
Hama
'82 KZ305-B1 Cafe Racer
'80 Z750E project
www.dotheton.com/forum/index.php?topic=59260.0
'82 KZ305-B1 Cafe Racer
'80 Z750E project
www.dotheton.com/forum/index.php?topic=59260.0
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- Rustyhama
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Re: Fork top removal?
25 Jun 2014 12:57
While we're on the fork subject. To remove the inner part from the lower leg the manual calls for the dreaded special tool for the top. Can this be avoided if I clamp the top tube back into the tree preventing the tube from turning? Or do I need to stop the piston itself from turning using the special tool or an improvised version?
Hama
'82 KZ305-B1 Cafe Racer
'80 Z750E project
www.dotheton.com/forum/index.php?topic=59260.0
'82 KZ305-B1 Cafe Racer
'80 Z750E project
www.dotheton.com/forum/index.php?topic=59260.0
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- pete greek1
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Re: Fork top removal?
25 Jun 2014 13:14
I have found that the best way to do it , is to drain the oil from the small screw, leave spring in, & top cap on, & use an impact gun to remove the square recessed nut on the bottom first , the compressed spring will help keep it from turning ..P. S. you may have to wrap it in something & put it in a vise to hold it
Pete
Pete
1980 LTD 1000..,1976 LTD 900, have the 1000&900 now. the rest are previous= 1978 KZ 650 B.., 1980 Yamaha XT 500..,1978 Yamaha DT 400.., 1977 Yamaha yz 80..,Honda trail ct 70.., Honda QA 50...5-1/2 hp brigs & straton CAT chopper mini bike...3-1/2 hp mini bike (WHEN GAS WAS ABOUT 45 CENTS A GALLON)!!!!
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- Rustyhama
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Re: Fork top removal?
25 Jun 2014 13:33
I assume you mean wrap the lower leg to hold it. Thanks for your response.
Hama
'82 KZ305-B1 Cafe Racer
'80 Z750E project
www.dotheton.com/forum/index.php?topic=59260.0
'82 KZ305-B1 Cafe Racer
'80 Z750E project
www.dotheton.com/forum/index.php?topic=59260.0
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- pete greek1
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Re: Fork top removal?
25 Jun 2014 14:29
Yes, ...Good Luck 
Pete

Pete
1980 LTD 1000..,1976 LTD 900, have the 1000&900 now. the rest are previous= 1978 KZ 650 B.., 1980 Yamaha XT 500..,1978 Yamaha DT 400.., 1977 Yamaha yz 80..,Honda trail ct 70.., Honda QA 50...5-1/2 hp brigs & straton CAT chopper mini bike...3-1/2 hp mini bike (WHEN GAS WAS ABOUT 45 CENTS A GALLON)!!!!
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- KZJOE900
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Re: Fork top removal?
25 Jun 2014 18:20 - 25 Jun 2014 18:20
When taking out the top plugs, make sure your face is not in the line of fire.
Current project 76 KZ900 (This was a Vetter model)
76 KZ900
81 XJ550H SECA (Current Project)
82 XJ550R SECA
Past:
86 FJ1200
74 Z1900
72 CB450
76 KZ900
81 XJ550H SECA (Current Project)
82 XJ550R SECA
Past:
86 FJ1200
74 Z1900
72 CB450
Last edit: 25 Jun 2014 18:20 by KZJOE900.
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- Rustyhama
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Re: Fork top removal?
26 Jun 2014 11:35
Thanks for all the advice on this process. I managed to get it done last night. Those circlips were damn fiddly but perseverance paid off there. The other tricky part was the allen bolts at the bottom. I bolted the fork to the dexion leg of my bench and turned the allen key with my big wrench, they were tight! Now I can do the lowering and paint the lower legs. New fork seals are in transit from the US.
Hama
'82 KZ305-B1 Cafe Racer
'80 Z750E project
www.dotheton.com/forum/index.php?topic=59260.0
'82 KZ305-B1 Cafe Racer
'80 Z750E project
www.dotheton.com/forum/index.php?topic=59260.0
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