Fork top removal?

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25 Jun 2014 12:23 #637973 by Rustyhama
Fork top removal? was created by Rustyhama
I need to check my fork oil level (among other things). The manual says 'remove the top plug and pull out the spring' but how do you get this thing out? Sorry if this is a dumb question...

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Hama

'82 KZ305-B1 Cafe Racer
'80 Z750E project
www.dotheton.com/forum/index.php?topic=59260.0
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25 Jun 2014 12:26 - 25 Jun 2014 12:27 #637974 by 650ed
Replied by 650ed on topic Fork top removal?
I may be wrong, but it looks like you would depress it in a little and remove the circlip. Ed

1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
Last edit: 25 Jun 2014 12:27 by 650ed.

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25 Jun 2014 12:32 #637975 by Rustyhama
Replied by Rustyhama on topic Fork top removal?
That looks like the answer thanks. I can do use it down a few mm which exposes the circlip. Then I should be able to hook it out with a small screw driver. Thanks Ed

Hama

'82 KZ305-B1 Cafe Racer
'80 Z750E project
www.dotheton.com/forum/index.php?topic=59260.0

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25 Jun 2014 12:57 #637977 by Rustyhama
Replied by Rustyhama on topic Fork top removal?
While we're on the fork subject. To remove the inner part from the lower leg the manual calls for the dreaded special tool for the top. Can this be avoided if I clamp the top tube back into the tree preventing the tube from turning? Or do I need to stop the piston itself from turning using the special tool or an improvised version?

Hama

'82 KZ305-B1 Cafe Racer
'80 Z750E project
www.dotheton.com/forum/index.php?topic=59260.0

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25 Jun 2014 13:14 #637980 by pete greek1
Replied by pete greek1 on topic Fork top removal?
I have found that the best way to do it , is to drain the oil from the small screw, leave spring in, & top cap on, & use an impact gun to remove the square recessed nut on the bottom first , the compressed spring will help keep it from turning ..P. S. you may have to wrap it in something & put it in a vise to hold it
Pete

1980 LTD 1000..,1976 LTD 900, have the 1000&900 now. the rest are previous= 1978 KZ 650 B.., 1980 Yamaha XT 500..,1978 Yamaha DT 400.., 1977 Yamaha yz 80..,Honda trail ct 70.., Honda QA 50...5-1/2 hp brigs & straton CAT chopper mini bike...3-1/2 hp mini bike (WHEN GAS WAS ABOUT 45 CENTS A GALLON)!!!!

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25 Jun 2014 13:33 #637982 by Rustyhama
Replied by Rustyhama on topic Fork top removal?
I assume you mean wrap the lower leg to hold it. Thanks for your response.

Hama

'82 KZ305-B1 Cafe Racer
'80 Z750E project
www.dotheton.com/forum/index.php?topic=59260.0

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25 Jun 2014 14:29 #637985 by pete greek1
Replied by pete greek1 on topic Fork top removal?
Yes, ...Good Luck B)
Pete

1980 LTD 1000..,1976 LTD 900, have the 1000&900 now. the rest are previous= 1978 KZ 650 B.., 1980 Yamaha XT 500..,1978 Yamaha DT 400.., 1977 Yamaha yz 80..,Honda trail ct 70.., Honda QA 50...5-1/2 hp brigs & straton CAT chopper mini bike...3-1/2 hp mini bike (WHEN GAS WAS ABOUT 45 CENTS A GALLON)!!!!

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25 Jun 2014 18:20 - 25 Jun 2014 18:20 #637998 by KZJOE900
Replied by KZJOE900 on topic Fork top removal?
When taking out the top plugs, make sure your face is not in the line of fire.

Current project 76 KZ900 (This was a Vetter model)
76 KZ900
81 XJ550H SECA (Current Project)
82 XJ550R SECA
Past:
86 FJ1200
74 Z1900
72 CB450
Last edit: 25 Jun 2014 18:20 by KZJOE900.

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26 Jun 2014 11:35 #638059 by Rustyhama
Replied by Rustyhama on topic Fork top removal?
Thanks for all the advice on this process. I managed to get it done last night. Those circlips were damn fiddly but perseverance paid off there. The other tricky part was the allen bolts at the bottom. I bolted the fork to the dexion leg of my bench and turned the allen key with my big wrench, they were tight! Now I can do the lowering and paint the lower legs. New fork seals are in transit from the US.

Hama

'82 KZ305-B1 Cafe Racer
'80 Z750E project
www.dotheton.com/forum/index.php?topic=59260.0
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