83 kz750 fork cap removal

Replaced the fork seals but I can't figure out how to remove the caps in order to fill with fork oil. On another bike the caps had either a hex head or socket fitting, but the caps on this bike just have perfectly round indentations. I have the manual and it just says to remove the caps to fill. :huh: The diagram makes it look like there's a circlip on top of the cap but I don't see that on mine.

Please help! Thanks.

Not familiar with your model but here is a link with the parts:

www.cmsnl.com/kawasaki-1983-kz750-f1-ltd...t/19070.html#results

Looks like it has a circlip that holds the top plug in place. Looks like a similar system used on my Yamaha XJ. To get it off, leave the forks mounted in the triple tree but release the top pinch bolt (the one on the triple tree holding the top of the inner tube) to free up the pressure on the plug. Then I used a very large screwdriver to push down on the plug while using a small blade screwdriver to pry out the circlip. Once the circlip was out the plug can freely come out from the top of the tube. This is just a guess, but by looking at the diagram, that looks to be the same on yours.

Joe

Thanks Joe! That sounds like it'll do it, I'll give it a try tomorrow and let you know. I appreciate the quick reply!

Troyn, forgot one very important point. Please remember the inner forks spring is putting upward pressure on that cap. So when you push it down with the screwdriver you are compressing that spring. So once the circlip is out, be careful it doesn't fire the plug at you . Don't put your face in its path. Don't ask me how I know, LOL.

Thanks, I'd like to avoid experiencing that first-hand!

Btw that worked, thanks! Weird way to do it I think...

Troyn, my apologies but another thing I forgot to mention. Probably cause I haven't got around to reassembling mine, LOL. I think it is recommended that you replace the circlips with new ones for safety's sake. See what your service manual says on the topic.

Thanks Joe, my manual doesn't say anything including how to remove the cap in the first place! They came out clean so I'm going to have faith they'll hold.

Hey how did you get the black "air" fitting off the top of the fork? It feels very tight and I am afraid to take it off. I am waiting for USPS to find my manual that they lost...

Black air Fitting? Do you talk about the air valve cap? Pics?

It was the two round air valves shown in the center of the screenshot. I just pulled up hard and they came off. My bike had a Vetter fairing on it, so I think it is missing some of the washers, and fittings on it. The two fittings have O-rings on the inside of them. My bike had a clamp holding the air fittings in place instead of the factory fittings that would be on it if it had headlight ears and such. I hope my manual gets here been waiting for weeks. USPS is holding it hostage I think.