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Table of Contents
230
CHAPTER TEN
b. Torque the fork mounting bolts as
specified in Table 2.
Disassembly
Refer to Figure 4 or Figure 5. Disassembly of
the fork leg requires special tools and patience.
If you have trouble taking the fork leg apart.
take it to your Kawasaki dealer to keep from
damaging it o r hurting yourself. Minor
variations exist among models. Pay particular
attention to the location and positioning of
spacers, washers and springs to make assembly
easier.
1.
On tnodels
~ ' i t h
airpressurizedforks,
release
any air pressure from the fork leg by removing
the rubber cap from the top of the fork and
pushing in the valve core until all pressure is
released.
2. Hold the upper fork tube in a vise with a
rubber sheet to grip the tube (Figure 6).
Remove the top plug by pushing the plug in and
prying out the circlip (Figure 7).
WARNING
The ,fork is assembled with spring
preload. Keep your ,face away .from the
fork end. The plug may spring out.
3. Remove the top plug and fork spring.
4. Remove the fork from the vise, pour the oil
out and discard it. Pump the fork several times
by hand to expel the remaining oil.
5. Clamp the fork slider in a vise with a rubber
sheet to grip the slider.
6. Remove the Allen bolt and gasket from the
bottom of the slider (Figure 8).
NOTE
The ,fork bottom Allen bolt is secured
with a locking agent and can be hard to
remove. After the Allen bolt is loosened,
it may not come out because the damper
rod base it screws into may turn with the
bolt. ! f a heavy duty air powered impact
wrench is available, try that first.
If
necessary, you may be able to keep the
damper rod base from turning by
tetnporarily installing the .fork spring
and cap, and having an assistant
compress the.fork while you remove the
bottom bolt. If these methods are not
sucessful, you will have to keep the
damper rod from turning with a special
tool on the end o f several socket
extensions. Your Kawasaki dealer has a
special tool (Figure 9), or you may find
thar a bolt with a 19 m m head (welded to
a long rod) wil1,fit the end of the damper
rod.
7. Slide the dust cap up off of the fork slider
and check for the presence of an oil seal
retaining clip with notches on the inside
(Figure 10).
If such a retainer is present, it must
be removed now with circlip pliers (Figure 11).
If the oil seal retainer is a smooth wire circlip
with several indentations (Figure 12), the clip
does not have to be removed until after the fork
tube is removed.
8. Separate the inner fork tube from the slider.
NOTE
Models with an oil seal retaining clip
with notches on the inside (Figure 10)
have 2 anti-friction bushings and a
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   Also See for Kawasaki KZ500

This manual is also suitable for:

Zx550Kz550Kzx550

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