I have a 81 kz650 and I'm trying to replace the fork seals. The problem I'm having is that the allen head bolt on the bottom of the forks is just spinning the insides. Any tips as to how to remove the stubborn bolt?
When I replaced the fork seals on my 1077 KZ650 I made a tool to hold things from spinning (See image below). Later, a company offered a tool that would do the same thing (see "DAMPING ROD HOLDING TOOL" at
). Before trying either tool you need to first determine if your bike's forks have smooth round holes or hex shaped holes. I know at least some of the later bikes had hex shaped holes and I don't think either tool I mentioned will work on those. Ed
1981 KZ650-CSR forks.
The head of the inner cylinder looks just like a 12-pt 19mm socket. 19mm = 3/4" approx.
I used a LH threaded bolt w nuts & long ratchet extensions. Some guys weld a nut to the threaded end of a long bolt.
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Tiger2126 wrote: I have a 81 kz650 and I'm trying to replace the fork seals. The problem I'm having is that the allen head bolt on the bottom of the forks is just spinning the insides. Any tips as to how to remove the stubborn bolt?
Hand-held impact tool or an electric / air impact gun:
Put the fork upside down on a piece of wood and apply some downward pressure
Use the hand-held or air / electric impact gun to remove the bottom bolt.
Motorcycle builder since 1973. Master Tech. Current bike: 1982 GPZ1100B2.
Most of the time I just loosen the allen screw while the fork is assembled with spring, then I pull the fork apart
First Permanent ride the Z1R since Dec1977 (220,000km) as of June 2015
Second permanent bike 1989 FJ1200 my work horse, growing on me, great bike.
Third ride is now the Frankenstein GPZ1100, now if only I can ride three bikes at once?
This is what I came up with, bolt welded to some rebar with a rebar handle welded to it, it works pretty good, I just wrapped some tape around it so it wouldn't damage anything inside. I had tried all the non-special tool methods before making a post, but there's a good chance that the forks have never been apart before I got a hold of the bike. Thanks for all the help with this, this is a pretty cool community!