Front fork special tool

Aloha guys.

It's been while to post anything here as I'm currently working on my other bike (89' ZX-7), but slowly collecting and working on small stuff on my GPz/KZ as well.

Now, just the other day, I was cleaning up my current stock of parts and came across some left over fork oil for my ZX-7. That got me to look at my KZ front fork and draw up some parts list that I need. Anyway, long story short, even if I decided to rebuild my front fork, I know I need to rebuild it because it sat for over 20 years or so and the seal are pretty much gone at this point.

So I know to disassemble these forks, I need special tools ( I believe the part # are 57001-183 and 57001-1011) according to Kawasaki manual. Now, I know these are long gone, so what do you guys use to disassemble the front fork when it need servicing? Sometimes, I know you can get away without using special tools when replacing seals only, but I want to check the condition of the internal because it sat for so long.

I can't remember how I did it 20-some years ago, and even if I decided to get a forks from evilbay, I still need/want to rebuild them anyway...........

You will need to see whether your bike's fork cylinders have a hex depression or a round hole in their top end. If they have a round hole like the ones on my 1977 KZ650-C1 you may want to make a tool like the one I made (below). Another option if the fork cylinders have round holes is the "Damping Rod Holding Tool" at www.racetech.com/page/id/70 Ed

I've done a couple of sets of forks. I use an impact on the hex bolt in the bottom of the fork. When putting it back together I put a broomstick down the fork tube and press it to hold the end of the damper from turning while I retighten the hex bolt.

Ojisan rider wrote: I know these are long gone...

Actually I just bought (and have received) 57001-1011 from Partzilla last week.

While still assembled try hitting the end of your ratchet with a rubber mallet. Most of the time the bolt will loosen, Tighten the same way.
Steve

If you use an impact on the damper rod bolt, usually you can just looslty assemble the fork, collapse a bit to put spring pressure on the damper and then tighten the bolt. The spring keeps it from turning.

Are you doing the 750-R1 forks? just wondering. Here's a recent topic with pics that shows a couple of homemade fork tools. I don't know if your damper rods are the same. I'd guess yes, but that is just a guess. I use the left-hand reverse threaded bolt-nuts fitted to a 19mm socket & ratchet extensions.

KZRider >> Forks KZ750H

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650ed wrote: You will need to see whether your bike's fork cylinders have a hex depression or a round hole in their top end. If they have a round hole like the ones on my 1977 KZ650-C1 you may want to make a tool like the one I made (below). Another option if the fork cylinders have round holes is the "Damping Rod Holding Tool" at www.racetech.com/page/id/70 Ed

Thanks Ed. I believe mine is square ones. I know I did it loooooooooooong time ago, but forgot how I did it. Yeah, I made some home-made tool to get it off. Don't you hate getting old? I still can learn some new stuff, but as soon as I learn something new, several old ones gets deleted from my real old hard-drive (aka brain).