Katit's 1978 KZ650 project

Forks apart. Nasty inside, it's not an oil. There was mixture of water, black goo and oil?

Question. What is this ring inside inner tube? I can feel it with a finger but it doesn't come out. Also, which parts should I replace inside? 


 

I've always used an impact wrench and the bolt comes right out of the bottom.  To tighten them up I have the correct tool.

Impact wrench didn’t work for me. Bolt was just spinning. What proper tool do you use to tighten?

wrote:

Impact wrench didn’t work for me. Bolt was just spinning. What proper tool do you use to tighten?

You need a tool to stop the damper from spinning.
It fits inside the stanction and locates in the damper body.
From the factory the damper bolt is thread locked which can cause the whole assembly to spin if not held with the damper tool.

I made special tool same as original. It’s 2 posts up. I was confused what correct tool hardrockminer refer to.

also examining parts - this tool does nothing but simply wedging/notching. 

wrote:

I made special tool same as original. It’s 2 posts up. I was confused what correct tool hardrockminer refer to.

also examining parts - this tool does nothing but simply wedging/notching. 

Yes! Some people just use a sharpened wooden broom handle.
Just be sure to remove any splinters. 

katit post=866391also examining parts - this tool does nothing but simply wedging/notching. 

Yeah, once I finally got my 650 forks apart I was surprised that there were no features on the damper rod to grab on to.  And then I was disappointed to learn that the factory special tool just jams a spike into the a taper on the rod.
I have used a broom stick more than once.  It really does work fine, and it's way cheaper than the special tool.  

Exactly. I didn’t understand there is nothing there and didn’t have broomstick. Sacrificed 1/2 extension, 1 minute on grinder made a factory special tool copy

I just realized....my tool is for Z1 forks.  It doesn't work on 650's.

Unsure if this will be helpful to say, but I've always been able to remove/install that bolt by hand as long as the fork spring is pressing on it. Could it be worth a shot to put the spring and cap on to try that way?

For reference 

 

Painting is not my strong side. For sure. Spent lot of time prepping/scuffing all the parts. Today I painted everything!!! I don't like this part. Mainly because I feel rushed and because I don't have proper environment. Weather was good but somewhat windy. I don't like wearing respirator either.

Paint goes in clumps, not sure if it's my gun or? And it dries pretty fast. There is a lot of overspray on a frame. I did my best, but oh well, it's "C" job. Separate parts came out better. But anyways, done is done. Better than it was for sure.