Help, lower fork bolt

Part number 44041-040.

I ordered the correct part number for my 1978 kz750 b4 but the bolts don't fit either fork piston. I can turn them only about a quarter turn and they sieze up. It's like its the wrong thread size.

But as I said, its the correct new stock oem part.

Anyone have this problem?

Did the new bolts come in an unopened Kawasaki package?
Will the old bolt threads thread back in?
Maybe try taking the old & new bolts to the hardware store to check them with a thread size gauge.

That's the same part number I used when I worked on my KZ650 forks, and the bolts worked perfectly. During assembly a non-permanent locking agent is used on the threads, so make sure the threads in the fork cylinders are clean. If they are clean and the allen bolts still do not thread in easily I suggest you take a fork cylinder and bolts to a machinist and have him check the threads with a thread gauge to make sure they match. It is possible you were shipped the wrong bolts. Ed

Maybe a PO changed the forks!

Any tips on cleaning out old thread lock from inside what the manual calls the fork "piston and cylinder unit". It would be easy to clean a bolt, but this is down inside.

Thanks!!!

You might be able to drag it out bit by bit using a dental pick. Ed

Do you have the old bolt? You can cut a slot in it to chase out the threads.
Steve

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