Forks rebuild 1980 Kz750 E1

philmountains
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Forks rebuild 1980 Kz750 E1

24 May 2025 00:20

Hi just about completed the forks rebuild , and want to check I'm reading this correct 310ml of oil to each fork.
oh and here are a couple of pics of the home made seal driver , worked great using a piece of 1 1/2 plastic waste pipe, and also a picture of the 19mm bolt welded to the T bar for holding the cylinder.

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Nessism
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Re: Forks rebuild 1980 Kz750 E1

24 May 2025 07:23

#912797

Your damping rod tool is nifty. I use a spark plug socket, with the extension inserted backwards, instead. No welding involved...

The hex on the bottom of the socket matches the hex in the damping rod.

Regarding oil, measuring by height is better than volume.

Ed
Carb O-ring Kits : www.kzrider.com/forum/3-carburetor/61807...-o-ring-kits?start=0

www.kzrider.com/forum/faq-wiki/618026-new-owner-things-to-know

1981 KZ750E2
www.kzrider.com/forum/11-projects/604901...z750e-project-thread

The following user(s) said Thank You: SWest, scubaanders, Gdizard, philmountains

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philmountains
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Re: Forks rebuild 1980 Kz750 E1

27 May 2025 07:09

#912908

Hi thanks for your help, well I've put in 232cc of oil in as recommended, and pimped thf forks up a little with hsnd pump, I'm going to buy one of those small digital tyre pressure gauges to get the pressure exact , at moment still holding the air in so can't bd bad .yes the wrench i made is a little niffty if not rough, I made it to fit the ZX9R forks, and just found a bolt that fit.
thanks again Phil

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philmountains
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Re: Forks rebuild 1980 Kz750 E1

06 Jun 2025 01:37

#913416

I'm really struggling here to find the correct answer, do you measure the front fork oil capacity, with the forks fully compressed or not ,with or without the springs, the manuals are really helpful.

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Wookie58
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Re: Forks rebuild 1980 Kz750 E1

06 Jun 2025 01:52 - 06 Jun 2025 01:57

#913417

Taken from the FSM in the filebase

1982 KZ1000 Ltd
www.kzrider.com/forum/11-projects/617631...-82-begins?start=192
kzrider.com/filebase-alias?view=download...d-fault-diagnosis&ca

...0 fork oil.jpg

Last edit: 06 Jun 2025 01:57 by Wookie58.

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philmountains
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Re: Forks rebuild 1980 Kz750 E1

06 Jun 2025 01:57

#913418

I'm really struggling here to find the correct answer, do you measure the front fork oil capacity, with the forks fully compressed or not ,with or without the springs, the manuals are really helpful.

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philmountains
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Re: Forks rebuild 1980 Kz750 E1

06 Jun 2025 02:02

#913419

HI Wookie , I might be just thick here, it does state fully compressed in the Haynes manual, cannot see anything in Kawasaki manual, nor can I find anything specific elsewhere, only a post re Z 750 twin.
Thanks again
Phil

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Wookie58
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Re: Forks rebuild 1980 Kz750 E1

06 Jun 2025 02:09

#913420

philmountains wrote:

HI Wookie , I might be just thick here, it does state fully compressed in the Haynes manual, cannot see anything in Kawasaki manual, nor can I find anything specific elsewhere, only a post re Z 750 twin.
Thanks again
Phil

The extract I posted is from the Kawasaki factory manual in the file base. It states spring removed and forks fully extended (also in the filling capacity chart it states "oil level without spring")