78 kz1000 A2 fork rebuild

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78 kz1000 A2 fork rebuild

21 Jun 2020 19:55
#828637
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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  • 650ed
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Re: 78 kz1000 A2 fork rebuild

21 Jun 2020 20:38 - 21 Jun 2020 20:40
#828638
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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Re: 78 kz1000 A2 fork rebuild

21 Jun 2020 20:47
#828640
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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Re: 78 kz1000 A2 fork rebuild

22 Jun 2020 04:41
#828644
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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Re: 78 kz1000 A2 fork rebuild

22 Jun 2020 04:46
#828645
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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Re: 78 kz1000 A2 fork rebuild

22 Jun 2020 07:10 - 22 Jun 2020 07:11
#828652
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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  • Kidkawie
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Re: 78 kz1000 A2 fork rebuild

22 Jun 2020 11:04
#828674
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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  • 9er rider
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Re: 78 kz1000 A2 fork rebuild

22 Jun 2020 13:05 - 22 Jun 2020 13:07
#828677
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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