TOPIC:

Man I'm doing bad today....it also says fork extended no spring.

650ed wrote: So is the spec in the FSM, which is 290CC of SAE 5W20 fork oil for the KZ550-C3, accurate or not accurate? Ed

I have no idea. I did have to add some after pumping to get to 18.7" but it says to take the springs out for the 78 and later models. Being a LTD probably requires more. and it's a 550 not a Z1 They are not all the same.
Steve

cbrianroll wrote: I'm at work so I can't verify but perhaps it's because an Ltd? Longer forks if I'm correct? Pretty sure my manuals just say kz550 etc

In that case you should toss out your manual and use the CORRECT one. For sure, different KZ550 models have different specifications, so using some generic manual or the manual for the wrong model will lead to mistakes. In other words use the Kawasaki Service Manual, and the supplement in that manual, for your specific year and model motorcycle. If your motorcycle is a 1982 KZ550-LTD it is in fact a 1982 KZ550-C3. Assuming that is the case, you can use the Kawasaki Service Manual at www.kzrider.com/modules/ServiceManuals/Kz400500550_79to83.pdf until you can buy a hardcopy. If you look at the very last page of that manual you will find that it includes the KZ550-C3. Be POSITIVE that you use the correct pages in the manual because it covers several models. Ed

Dang, messed that up. It's an 80 kz550 c Ltd. Is there a Ltd book? I can't find one, I have manuals that say c....is that not mine?

Well....i put myself in dumby mode and read all three manuals. I've come up with the measurement is the important number, not the amount of fluid. Will try that and post results.

650ed wrote: So is the spec in the FSM, which is 290CC of SAE 5W20 fork oil for the KZ550-C3, accurate or not accurate? Ed

Ed, the problem is in all the 550 manuals. They give both a volume and oil level for each model, but one or the other is incorrect. To wit-- I believe the fsm for the C1 calls for 290cc of oil and a measured level of 335mm. If you put 290cc of oil in the fork, the level will be nowhere near 335. It takes far more than 300cc to reach the specified level. You can have the specified volume or you can have the specified level, but not both. Which should it be? Nobody seems sure.

As long as the measurement is correct.......

I suspect the volume is more likely correct than the level measurement (from top with springs out). The volume is more than that of the standard forks, which makes sense, but the published level measurement is drastically different than that of the other Kz550's. I think the Kz550C 's published level measurement is an error in the FSMs and third party manuals.

After filling the fork with the specified volume, it is normal to have the oil level be below what the published level measurement specifies by maybe 10 or 20 mm. So you have to add a bit more oil to get up to the published level measurement.

So my guess is that the level should be 456 or 556 instead of 356. Because the fork is longer, I would have expected more clearance from the top of the oil level to the top of the fork. So 556 would have been more likely, but the two owners who have done measurements seem to be saying it is closer to 456. Either way, "356" appears to be way off.

The original poster from this thread, "GTO6T6", says he was at 356 + 107 = 463mm clearance when he added 290ml (the published dry volume) of oil.

The original poster from the other thread, "TheProletariat", says he had more than 18" (457mm) clearance when he added 270 ml (the published wet volume) of oil.

Those two owners seem to agree. When adding the published volume of oil, the oil level ends up somewhere slightly lower than 456mm from the top. Adding a bit more would get them to 456mm.

Loudhvx...you sound like you got it nailed lol, I only got as far as adding oil, pumping forks, add more level to 14in. Next step I was gonna drain it and see what comes out and try to adjust accordiugly. I bought royal purple, 5w20 like the book says, would you guys suggest something different? I live on west coast, wa state. Temp varies from 20 ish to maybe 90 at the highest. Thanks all you guys for your input, I tend to overthink things and complicate them.

cbrianroll wrote: ...... I bought royal purple, 5w20 like the book says, would you guys suggest something different? .....

Royal Purple what? I hope you didn't use motor oil. You are aware that forks take fork oil, and fork oil is not the same as motor oil. Bel Ray makes what I and many others consider to be the best fork oil. I've been using it in my KZ650 for 40 years, changing it every 2 years, and have never had any fork seal leaks or other fork problems. The wide variety of weights (see link below) can be mixed to achieve whatever level of stiffness one desires. Ed

www.belray.com/bel-ray-high-performance-fork-oil

Just like the manual says...sae 5w20. I m goona have belray coming by amazon, workung out the hiccups with at least decent oil.

The FSM specifies SAE 5W20, as in motor oil. It didn't qualify it as any special type of fork oil.