Front fork part diagram

martin_csr wrote: 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)
They are not listed as a separate part, so you can't order them from Kawasaki or Partzilla.
However & if necessary, some guys replace the bushings by ordering from a bushing supply company,
If yours need replacing, you would have to measure them somehow. I've never replaced a bushing & don't know where to get them.

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. ????

1.
I have taken measurements, please see photos:
temp.dynamitt.net/div/MC/fork/02/
Could these be corect?
www.z1enterprises.com/fork-seals-36x48x105-kawasaki.html
How can I determine from these if I have D2 SR or 750E?

2.
How tight shall the steel cylinder goes through the bushing?
Shall it be some loosens? how much?
I can try to make a movie of it?

3.
Something who shall be replaced?

4.
I understand, I will analyze more.

5.
temp.dynamitt.net/div/MC/fork/IMG_5393.JPG
As you can see there was some ring laying on the oil seal ring?


In general I want my suspension back in good condition

Thank you all.

1. You need to measure the height H of the oil seals & dust shields.
The D2 SR oil seals & dust shields are taller than the 750E. Oil seals. D2 SR = 36 x 48 x 10.5 H. .... 750E = 36 x 48 x 8/9.5 H

3. Those plastic spacers are not available as a separate part. I've never heard of anyone replacing them & I don't know if any replacement substitute parts are available.

5. That ring may be the big fork seal washer. D2 SR #21 >>> 44043-044. or 750-E2 >>> WASHER 92022-1275 (no picture)

martin_csr wrote: 1. You need to measure the height H of the oil seals & dust shields.
The D2 SR oil seals & dust shields are taller than the 750E. Oil seals. D2 SR = 36 x 48 x 10.5 H. 750E = 36 x 48 x 8/9.5 H

3. Those plastic spacers are not available as a separate part. I've never heard of anyone replacing them & I don't know if any replacement substitute parts are available.

5. That ring may be the big fork seal washer. D2 SR #21 >>> 44043-044. or 750E >>> not listed.

1. Please see:
temp.dynamitt.net/div/MC/fork/03/

3.
Okey, but see these picture the "sanding" who has been done on the steel, what is these ? nothing to focus on?
temp.dynamitt.net/div/MC/fork/steel.jpg

5.
I understand, but I can just reuse it, not wear and tears as I understood? Just clean it with some soap water.

6.
Please see attached picture, it was a metal "ring" as these on top of the oil seal on my forks also.
I added picture yesterday:
temp.dynamitt.net/div/MC/fork/IMG_5359.JPG
But it fall in two parts when I disabled yesteday.

1. Fork oil seals. You may be measuring wrong. Do not compress the rubber. just barely touch the rubber with your calipers.
I bet they are closer to 8/9.5 mm. re-measure >>> guessing >>> pic 01.jpg = 8mm & pic 02.jpg = 9.5 mm. >>> 750E

3. The upper fork tube appears to be worn. not good. You probably need new bushings & maybe new fork tubes. not sure. ???
This may not be so easy in Norway, but I would consider replacing the forks.

5. Yes. reuse it if it isn't damaged. It is listed in the 81 750-E2 fork parts list. The 750-E1 drawing does not show the big fork seal washers.

6. The old rusty circlip crumbled from corrosion. Replace the circlips.

martin_csr wrote: 1. Fork oil seals. You may be measuring wrong. Do not compress the rubber. just barely touch the rubber with your calipers.
I bet they are closer to 8/9.5 mm. re-measure >>> guessing >>> pic 01.jpg = 8mm & pic 02.jpg = 9.5 mm. >>> 750E

3. The upper fork tube appears to be worn. not good. You probably need new bushings & maybe new fork tubes. not sure. ???
This may not be so easy in Norway, but I would consider replacing the forks.

5. Yes. reuse it if it isn't damaged. Assuming it is a necessary part. The 750-E1 drawing does not show the big fork seal washers.

6. The old rusty circlip crumbled from corrosion. Replace the circlips.

1.
I remeasured 6mm and 8mm, when it touch really softly.

3.
When I drag my finger over the discolor, I can barely feel it, these part of the steel fork shall not seal anything, its in the bottom of the outer fork cylinder?

5.
ok

6.
ok,
Have we now concluded the part diagram I shall follow is
www.partzilla.com/catalog/kawasaki/motor...-kz650-d2/front-fork ???
So for these part (circlips) we are talking about item 20?

I don't know what diagram you should use. Your fork seals are measuring too small, and they are closer to the 750E size.
Since your bike is a 1981 model, I would use the 1981 KZ750-E2 fork parts diagram. Since there isn't a drawing, use the 1981 KZ650-H1 CSR fork diagram/drawing --- the csr has many of the same fork parts as the E2.

Fork dust shields. yours measure 24 mm >>> temp.dynamitt.net/div/MC/fork/03/03.jpg
Mine also measure 24 mm. My 1981 650-CSR has the same fork dust shields as the 750E.
www.z1enterprises.com/fork-dust-cover-2-kz650-kz750.html >>> 650H. 750H. 750E.

The 650-D2 fork dust shields appear to be taller to my eye.
www.z1enterprises.com/fork-dust-covers-k...900-kz1000-pkg2.html >>> 77-80 KZ650. B/C/D/E/F models.