78 kz1000 A2 fork rebuild

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21 Jun 2020 19:55 #828637 by PFD
78 kz1000 A2 fork rebuild was created by PFD
I’m putting my forks back together after replacing the fork seals and have a question, torque specs for the allen bolt of the damper piston is 14.5-19.0 ft-lbs according to my factory manual.

I can’t for the life of me get the damper piston to stop spinning to torque it to spec, does anyone have some advice or tips they can give me? The top of the piston only has a hole, not a top nut.

I’ve installed the spring and top cap hoping there was enough tension as well as jammed the tapered end of a socket extension into the hole of the piston but it wouldn’t stop it from spinning enough to hit the proper torque, any help would be appreciated.

Here’s what the piston looks like.


78 Kz1000A2, 77 Cb750K daily rider, pinstriper and signpainter

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21 Jun 2020 20:38 - 21 Jun 2020 20:40 #828638 by 650ed
Replied by 650ed on topic 78 kz1000 A2 fork rebuild
That looks like the fork cylinder on my 1977 KZ650-C1. Here's what I did so I could remove it and then torque it properly when putting it back together...........


1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
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Last edit: 21 Jun 2020 20:40 by 650ed.

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21 Jun 2020 20:47 #828640 by PFD
Replied by PFD on topic 78 kz1000 A2 fork rebuild
Thanks 650ed, I used a bit of hillbilly engineering and got things torqued properly. A broomstick and a ratchet strap worked well, on to the brake calipers I go!

Cheers


78 Kz1000A2, 77 Cb750K daily rider, pinstriper and signpainter

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22 Jun 2020 04:41 #828644 by Mikaw
Replied by Mikaw on topic 78 kz1000 A2 fork rebuild
In the future this is the tool you need. Pretty easy to find.

1976 KZ 900 A4 kzrider.com/forum/11-projects/613548-1976-kz-900-a4
1976 KZ 900 B1 LTD
1978 KZ 1000 B2 LTD
1980 KZ 750 E1
Kowledge Speaks, But Wisdom Listens.
Jimi Hendrix.
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22 Jun 2020 04:46 #828645 by Mikaw
Replied by Mikaw on topic 78 kz1000 A2 fork rebuild

1976 KZ 900 A4 kzrider.com/forum/11-projects/613548-1976-kz-900-a4
1976 KZ 900 B1 LTD
1978 KZ 1000 B2 LTD
1980 KZ 750 E1
Kowledge Speaks, But Wisdom Listens.
Jimi Hendrix.

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22 Jun 2020 07:10 - 22 Jun 2020 07:11 #828652 by 650ed
Replied by 650ed on topic 78 kz1000 A2 fork rebuild
Here's another option "DAMPING ROD HOLDING TOOL" . Ed

www.racetech.com/page/id/70

1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
Last edit: 22 Jun 2020 07:11 by 650ed.

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22 Jun 2020 11:04 #828674 by Kidkawie
Replied by Kidkawie on topic 78 kz1000 A2 fork rebuild
Put the fork completely together, compress it, then tighten the damper bolt. If you have a 3/8" impact you can just bump it tight with that.

1975 Z1 900
1994 KX250 Supermoto
2004 KX125

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22 Jun 2020 13:05 - 22 Jun 2020 13:07 #828677 by 9er rider
Replied by 9er rider on topic 78 kz1000 A2 fork rebuild
I have an old octagon pry bar that is tapered on one end I had dug up in Aspen Colorado that had been buried about 40- 50 years. I cleaned it up and the rust pits are a perfect grip for rebuilding forks.

76 kz 900 1075 76 kz 900 a4 78 kz 1000 ltd
Last edit: 22 Jun 2020 13:07 by 9er rider.

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