Front fork washer

When I assembly the front fork I forgot to install the washer item number 22022 on attached photo.
I don`t think it will be a issue, the oil seal should be tight anyway?
The only problem if the oil seal are able to move up and down, if it`s not tight against the 92033 RING-SNAP,FORK OIL.... ????

Shall I open everything again..... ?

Without the washer the guiding sleeve #46065 can move up and down, could be destroy the seal #92049.
It is an easy in and out job with the right tools. You will regret it later on not to do it right now.
Don´t been so lazy on your project bike. It is for your own safety!!!

I tried to install the washer today, but there was not enoufh space for it, the ring snap was not able to lock/latch...
I found another fork diagram:
www.partzilla.com/catalog/kawasaki/motor...-h2/front-fork-80-h1

There are they not using a washer, when I took a closer look today, there are not much space between the oil seal and the ring snap...

Cross my fingers

Is the guiding sleeve #46065 from your first post in position or is there no sleeve in the fork tube?
Have you put in the washer on the other fork tube????
What fit in one fork tube must fit in the other fork tube.

I have installed new sleeve, I see your point sleeve can damage the oil seal from underneath. The sleeve is not lose, I used force to get in position. I have tried the new washer in metal and also the old in plastic, and both was to thick....

I think the new oil seal is ticker then the old... there is the problem....

There is not washer on noon of the forks....

As I see it can I gamble the sleeve is not loosing or try another oil seal....

In my opinion the seals high with the washers are a little thinner ( 0,5 - 1,0 mm).
Have you compared the new seals with the old ones???
Are their any numbers on the seals to compare??? (OD - ID - High)

Just realized you have a 650 not a 750 bike:pinch: :pinch:
There are two different seal dimensions

OD 43 mm/ID 36 mm/ High 11 mm (click on tab "Technische Daten")

www.biketeile24.de/de/fahrgestell/vorder...er-gabel-55-109.html



OD 43 mm/ID 36 mm/ High 10,5 mm (click on tab "Technische Daten")

www.biketeile24.de/de/fahrgestell/vorder...z-p40fork455036.html

Thank you,

I will measure the old new and check dimension. When I open up the forks first time there was a plastic washer, but it was larger so it was not cover over the "opening" whole where the sleeve can come up, it was only covering the until the edge. So these mean there was not more protection before then now.

I will measure the old seal to see, because if the new had been same size wheel it be space for a washer under to lock the sleeve for moving.

The oil seal I have installed is 92049-1101.

What upper fork tubes did you install? if possible, post the part number. The 1980 750E diagram doesn't show the washer.

note: his bike is a 1981 650-D4 SR, so there are no diagrams for the forks. the 81 650 pdf manual covers the D4 & may be available on this site somewhere. the upper tubes were worn, so 750E fork tubes & fork seals were installed. the D4 forks are similar to the 750E, but they are not identical & some of the parts have not swapped or fit perfectly.

martin_csr wrote: What upper fork tubes did you install? if possible, post the part number. The 1980 750E diagram doesn't show the washer.

note: his bike is a 1981 650-D4 SR, so there are no diagrams for the forks. the 81 650 pdf manual covers the D4 & may be available on this site somewhere. the upper tubes were worn, so 750E fork tubes & fork seals were installed. the D4 forks are similar to the 750E, but they are not identical & some of the parts have not swapped or fit perfectly.

The ebay seller state the upper fork is #39093-1067

The upper fork tubes shouldn't affect how the washer & fork seals fit. I wasn't thinking earlier. doh.

Did you measure the new fork seals before you installed them?
Is it possible there's an extra washer in the lower/outer fork tubes? probably not. but just in case.

martin_csr wrote: The upper fork tubes shouldn't affect how the washer & fork seals fit. I wasn't thinking earlier. doh.

Did you measure the new fork seals before you installed them?
Is it possible there's an extra washer in the lower/outer fork tubes? probably not. but just in case.

No extra washing, everything in lower fork was removed....

And when I start remember when I removed all the old parts some moths ago, there was no washer above the sleeve so...
then it has been wrong from before I recive the bike also,

I will keep it like these and keep and eye on it.