Front fork part diagram

I have a 1981 KZ650-D4, but are not sure if the front fork is orginal, but I think so?
I have attached some picures, somebody know if the part diagram I found could be correct one?

www.partzilla.com/catalog/kawasaki/motor...ont-fork-81-82-h1-h2

I have not open up the front fork, but from the out side it looks to be identical.

The D4 SR 650 uses a straight leg fork. Not that leading axle jobby from the H model bikes.

www.dropbox.com/s/5txmjtehww5uq3i/Z650%2...Service%20Manual.pdf

Similar forks: 78-79 650 SR. 80-82 750E. dual disk & center axle type.
The 750E forks are probably the closest match >>> see 750-4 pdf manual. diagram on pg 142.

www.partzilla.com/catalog/kawasaki/motor...nt-fork-80-kzy-50-e1 ...<<< ...(1980 KZ750-E1)

The 650H & 750H forks are very similar internally to the 750E, so for disassembly & assembly any one of those diagram drawings will probably suffice (diagram tegninger = nok, lignende, nesten det samme).

Be sure to note the specifications for the 650-D4 in the 1981 KZ650 manual, especially the fork free spring length.
Even if within spec, you might want to replace the springs.

martin_csr wrote: Similar forks: 78-79 650 SR. 80-82 750E. dual disk & center axle type.
The 750E forks are probably the closest match >>> see 750-4 pdf manual. diagram on pg 142.

www.partzilla.com/catalog/kawasaki/motor...nt-fork-80-kzy-50-e1 ...<<< ...(1980 KZ750-E1)

The 650H & 750H forks are very similar internally to the 750E, so for disassembly & assembly any one of those diagram drawings will probably suffice (diagram tegninger = nok, lignende, nesten det samme).

Be sure to note the specifications for the 650-D4 in the 1981 KZ650 manual, especially the fork free spring length.
Even if within spec, you might want to replace the springs.

Thank you all, i have some questions,

1. The top of the cylinders are not identical, I have a rubber cover? Please see attached photos.
It it just to make it "nicer" to look at?

2. With item number has the "fork free spring" you mention? 18 ? who is not available?

3. I want to get he front fork in top condition, is it a good option to replace all parts on the fork except 4, 8, 9, 14, 16, 17, 20 and 23 replace rest?

4. Is there a special oil who shall be used within the fork?

Your forks may be more similar to the 78-79 KZ650-D1/D2 SR models.

www.partzilla.com/catalog/kawasaki/motor...-kz650-d2/front-fork ... <<< ... 1979 650-D2 SR

If your fork springs need replacing, a common upgrade is new springs from Progressive Suspension. Z1Enterprises.com has them.

At the least replace the fork seals & dust shields. plus the springs. also, maybe the cap o-rings & maybe the fork seal circlips.
In the D2 SR diagram. 4, 16, 19, 20, 22. .... maybe not 4 & 20.
Some guys replace the bushings (not listed as a separate part). Replace them only if it's absolutely necessary.
Bushings >>> 1981 KZ650 pdf manual. see info & photo on pg. 4-15

Use motorcycle fork oil. The manual may specify 10W but some guys prefer 15W. some use a 50/50 mix of 10W + 15W.

Thank you all for your feedback, will take a look these the next days and order the parts.

martin_csr wrote: Your forks may be more similar to the 78-79 KZ650-D1/D2 SR models.

www.partzilla.com/catalog/kawasaki/motor...-kz650-d2/front-fork ... <<< ... 1979 650-D2 SR

If your fork springs need replacing, a common upgrade is new springs from Progressive Suspension. Z1Enterprises.com has them.

At the least replace the fork seals & dust shields. plus the springs. also, maybe the cap o-rings & maybe the fork seal circlips.
In the D2 SR diagram. 4, 16, 19, 20, 22. .... maybe not 4 & 20.
Some guys replace the bushings (not listed as a separate part). Replace them only if it's absolutely necessary.
Bushings >>> 1981 KZ650 pdf manual. see info & photo on pg. 4-15

Use motorcycle fork oil. The manual may specify 10W but some guys prefer 15W. some use a 50/50 mix of 10W + 15W.

1.
Please see attached order list, do I have what I need to get the fork in good condition again, almost good as new?

1.
The spring upgrade from z1enterprize, Progressive Suspension are they better Kawa orginal part?
Or are they same quality, but just cheaper? how can I find the correct one on the webpage they have many?

Thank you.

Nobody really knows what forks you have. Your fork dust boots (dust shields) in your photos appear to be the same size as the 750E, so you may need to use the 750E fork diagram. The 79 D2 SR dust boots & fork seals are taller than the 750E. Z1Enterprises.com has the measurements. I would disassemble the forks, then measure the fork seals & compare the other components to the D2 & 750E fork diagrams. I just compared the dust boots today. doh.

Ingen vet virkelig hva gafler du har. Gaffelstøvskjermene i bildene dine synes å være like store som 750E, så du må kanskje bruke 750E-gaffelskjemaet. 79 D2 SR støvskjermene og gaffeltetningene er høyere enn 750E. Z1Enterprises.com har målingene. Jeg ville demontere gaffelene, deretter måle gaffeltetningene og sammenligne de andre komponentene til D2 og 750E gaffeldiagrammer.

martin_csr wrote: Nobody really knows what forks you have. The fork dust boots (dust shields) appear to be the same size as the 750E, so you may need to use the 750E fork diagram. The 79 D2 SR dust boots & fork seals are taller than the 750E. Z1Enterprises.com has the measurements. I would disassemble the forks, then measure the fork seals & compare the other components to the D2 & 750E fork diagrams.

Gaffelstøvler (støvskjold) ser ut til å være i samme størrelse som 750E, så du må kanskje bruke 750E gaffeldiagrammer. 79 D2 SR støv støvler og gaffel tetninger er høyere enn 750E. Z1Enterprises.com har målingene. Jeg ville demontere gaffelene, deretter måle gaffeltetningene og sammenligne de andre komponentene til D2 og 750E gaffeldiagrammer.

Thank you, will open up the forks during these week before any parts is been ordered.
I will keep all posted

Today have I disabled one of the fork, please see photo taken here:
temp.dynamitt.net/div/MC/fork/

The fork was marked on the outside with:
K749XX (the XX was not able to read it)
1 L

Question 1:
It looks to be correct diagram martin have posted, or ?
www.partzilla.com/catalog/kawasaki/motor...-kz650-d2/front-fork

Question 2:
I have one more question, if you take a look at these picture:
temp.dynamitt.net/div/MC/fork/IMG_5358.JPG

The tube fork inner who is gliding against these copper? ring (brun ring), now there are some looseness between the copper ring and the steel fork (the copper ring opening is bigger then diameter n the steel fork), shall it be like these or is these wear and tear and these copper ring shall be replaced? I cannot see it on the diagram?

Question 3:
Please take a look at these picture:
temp.dynamitt.net/div/MC/fork/IMG_5382.JPG
Has these ring the same function?
Is it these two rings on questions 1 and 2 or shall remove any looseness?

Question 4:
temp.dynamitt.net/div/MC/fork/IMG_5380.JPG
The studs has not same dim. original they was? so a preview owner has got problem and install a larger one?


Thank you all for your inputs.

No eBay APP ID and/or Cert ID defined in Kunena configurationI don’t have access to a parts diagram for the KZ650-D4. However, the parts diagram for the KZ650-D2 (see

www.powersportswarehouse.com/p/Kawasaki#...50-D2-1979/070053D-8

shows the fork studs to be part number 92004-1009. A picture of fork stud 92004-1009 can be seen at the second link below. Neither of the fork studs in your picture looks like 92004-1009. Ed

1. measure the fork oil seals and fork dust shields. Then compare the measurements at Z1Enterprises.com.
If the measurements are the same as the D2 SR, then use that diagram.
Or if the measurements are the same as the 750E, use that diagram.

2. copper ring = bronze bushing. Those copper rings are bushings. probably made of bronze. (copper ring or brun ring)
[strike]They are not listed as a separate part, so you can't order them from Kawasaki or Partzilla[/strike].
Edit: the bronze bushingss are in the parts list for the 1981 750-E2. They are not in the 750-E1 diagram.
Edit: 1981 KZ750-E2 >>> BUSHING-FRONT FORK 44065-1016 >>> bronze bushing >>> bronze wear ring
Pyramid parts.. google search = motorcycle fork bushings

3. Yes, I think that plastic spacer acts as a bushing. My forks have them.
All of the 650 & 750 forks I've seen have a white plastic spacer like that. Your spacer may be discolored.

4. Yes, the previous owner may have damaged the stock stud, then re-threaded the orifice to a larger size.
I'm not sure if that larger size is okay. I'm wondering if over boring the orifice would weaken the fork leg. I don't know. ????