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TOPIC: KZ440 Fork Caps Won't Come Out

KZ440 Fork Caps Won't Come Out 12 Jul 2019 10:43 #807436

  • Jaytraeg
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Howdy folks, back at with the my 1981 KZ440 LTD if you've been following the excitement of this bike. This time, I'm trying to replace the oil in the forks.

I drained all the oil out, and when I went to take the caps off the forks on top I couldn't get them out. They are the circlip-type caps and I did remove the circlip, but they just won't come out. I can compress the caps, and they do move freely downward, but they seem to just hit a stopping point before coming out. Am I missing something? Also, they are not the air forks that the 1983 model got. Thanks folks!
1981 KZ440 LTD

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KZ440 Fork Caps Won't Come Out 12 Jul 2019 11:40 #807440

  • Scirocco
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Try to put some compressed air into the drain bore with the fork leg upside down in a bucket to catch the caps (for safety's sake).

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Last edit: by Scirocco.

KZ440 Fork Caps Won't Come Out 12 Jul 2019 12:00 #807441

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Damn, that would be a really good idea actually. The only problem is that I'm away at school, and don't have a compressor or a jack stand to get the front wheel off to take the forks off. Thanks anyway though!
1981 KZ440 LTD

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KZ440 Fork Caps Won't Come Out 12 Jul 2019 13:39 #807443

  • martin_csr
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I would loosen the upper triple tree clamp & spray some solvent or penetrant onto the fork caps to clean them. guessing there's probably crud around the fork caps. or maybe the o-rings have hardened. heat might also help, but you'd have to remove the forks. For stuff like this I use Liquid wrench silicone spray lubricant or LW penetrating spray. Keep in mind that the fork caps are under spring pressure and could go flying & get you in the eye.


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Last edit: by martin_csr.
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