GPz 1100 B2 - front fork disassembly???

OnkelB wrote: So the rest of the operation went smoothly (after fabbing a couple of tools I needed for the assembly) and everything is back together again.

However, I discovered a major discrepancy between the Clymer and the FSM regarding fork oil capacity and oil level.

According to Clymer the dry fork oil capacity for the 1100 B is 343 cc / 11.6 oz. and the oil level should measure 120 mm / 4.7" with the leg vertical, fully compressed and spring removed. For the same condition the FSM says 322 cc / 10.8 oz. and 164 mm / 6.4".

That's a difference of 21 cc / 0.7 oz and 44 mm / 1.7" :blink: - are they even speaking of the same model?

Should add that the FSM I have in digital copy covers the 1000 J, K and M models with a supplement for the 81, 82 and 83 1000s-1100s, my Clymer covers the KZ, ZX and ZN 1000-1100s as well as the 1000 P series.

Though I dont' consider the Clymer quite as bad as it's reputation I obviously trusted the FSM - if anyone has a manual specific (or more specific) to the GPz B-models and could be bothered to check I would like to hear if those numbers (322 cc / 164 mm) are correct.

My experience and opinion would be that I have heard and seen many examples where Clymers is mistaken, and when I come across discrepancies like this I always always always go with the FSM. The supplemental will say something like "refer to page 13 while keeping in mind X, Y and Z". Meaning same procedure as shown on page 13 just change this, this and this. So I would follow FSM and keep any of the supplemental information in mind and change the normal procedure to adjust to what the supplement for yours says. Hopefully that wasn't too convoluted or confusing HAHAHA :S

Brett

OnkelB wrote: if anyone has a manual specific (or more specific) to the GPz B-models and could be bothered to check I would like to hear if those numbers (322 cc / 164 mm) are correct.

The FSM that I have for the KZ1000 and KZ1100 models, and that has a Supplement section for my KZ1100B ('81 GPz1100), shows fork oil level should be 120mm +/-2mm, and fork oil capacity should 343cc +/-4cc.

Sorry for not replying before, been out of town for some days.

Upon rechecking the FSM I have, you're correct that the manual does indeed say 120 mm / 343 cc for the 81 1100-B1. I missed that the first time around since my bike is an 82 1100-B2 (it's in my sig, but I should have mentioned that), so I only checked the 82 supplement... :blush:

Anyway, think I figured it out. There are some differences between the 81 and 82 forks. As far as I can tell the 81 (B1) doesn't have the plugs/spring seats that are shown in the first pic in this thread. These plugs are sunk some 2-3 inches deep in the fork leg, so it makes sense that the oil capacity/level would be be lower than the 81. There is also a difference in spring free length as well as the position of the air valve - the 81 has separate air valves located at the the top of the fork, the 82 has a single air valve located right above the lower fork clamp with an equalizer tube connecting the two fork tubes. It seems that the Clymer lifted and listed the specs for the 81 B1, applied them to both models and missed these differences.

As already mentioned I trusted the FSM specs for the 82 and filled the forks accordingly - I like my suspension on the firm side so I went with 20W Bel-Ray and after taking the bike out for a couple of hours this afternoon I think I'm good. Everything feels tight and solid and best of all, no more weeping seals.

Glad it all worked out for you, thanks for sharing the end result

Brett