OK what am i missing? Fork rebuild question.

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09 Aug 2012 21:42 #541613 by doped304
So i am a proud owner of a 78 650 c2 basket case and I need some help. I took apart my front forks to powdercoat the fork tubes. Unfortunately this was about one year ago any one house move later. I have a shop manual that deals with air style forks and mine are the non air versions. I was looking on kawasaki. Com under my year model and the only thing it looks like I am missing is what appears to be a lock washer that goes on the top of the fork cylinder on top of the spring. Is this necessary? Can I use a hardware store lock washer?
Also on the springs themselves there is a flared washer type insert in one end, are the supposed to be one one each end or just the bottom?
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09 Aug 2012 21:59 #541618 by vintagebiker
Replied by vintagebiker on topic OK what am i missing? Fork rebuild question.
BikeBandit.com
Here is a link to your bike.It is a great site to use for reference.

www.bikebandit.com/houseofmotorcycles/19...b/o/m150630#sch82789

If all else fails, JUMP!

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09 Aug 2012 22:01 - 09 Aug 2012 22:03 #541620 by 4TheKZ1000
Replied by 4TheKZ1000 on topic OK what am i missing? Fork rebuild question.
I think you are missing (fork seals, scraper, c-clips and copper washers/seals for bottom allen bolt).
Last edit: 09 Aug 2012 22:03 by 4TheKZ1000.

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09 Aug 2012 22:19 #541623 by doped304
Replied by doped304 on topic OK what am i missing? Fork rebuild question.
Oh yeah I forgot the new stuff!
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09 Aug 2012 22:27 #541624 by 650ed

4TheKZ1000 wrote: I think you are missing (fork seals, scraper, c-clips and copper washers/seals for bottom allen bolt).


+1 The copper washers are called gaskets (#50) in the diagram but they are in fact flat copper washers. I don't believe you are missing any lock washers on top. Take a look at page 124 in the attached manual:

www.scribd.com/doc/48655900/Kawasaki-KZ-...B1-77-Service-Manual

1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)

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09 Aug 2012 22:44 #541629 by doped304
Replied by doped304 on topic OK what am i missing? Fork rebuild question.
OK if you click the bike bandit link vintage provided and look at #25 is that a lock washer on top the spring?

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09 Aug 2012 22:52 - 09 Aug 2012 22:58 #541635 by 650ed
no. The book calls it a piston ring. Ed

1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
Last edit: 09 Aug 2012 22:58 by 650ed.

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09 Aug 2012 23:07 #541639 by wireman
Replied by wireman on topic OK what am i missing? Fork rebuild question.
Would that be the seal on dampner assembly? B)

posting from deep under a non-descript barn in an undisclosed location southwest of Omaha.

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09 Aug 2012 23:24 #541646 by doped304
Replied by doped304 on topic OK what am i missing? Fork rebuild question.
I could see that, the maroon piston seal does have a gap in it and would look like a lock washer in an exploded view. That was my biggest concern, it looks as if I've got everything. I guess this model does not have any big bushings as found in 1000s or 900s I have seen in the past.

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