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Table of Contents
CHASSIS
235
Assembly
1 . See Figure 4 or Figure
5. Put the damper rod
spring onto the damper rod and insert them
into the top of the fork tube (Figure 14).
2. On models with anti-friction bushings,
make sure that the slider's bushing, the washer
and the oil seal are in place on the fork tube
(Figure 16). Install the seal with the numbered
or marked face up. The slit in the anti-friction
bushing should face the right-hand or left-hand
side of the fork slider.
3.
lnsert the damper rod base onto the end of
the damper rod (Figure 16).
4. Insert the fork tube into the slider. Apply a
locking agent such as Loctite Lock N' Seal to
the threads of the bottom Allen bolt before
installing it with its washer and torque the bolt
as specified in Table 2. T o keep the damper rod
base from turning, use the same method you
used during disassembly.
5. Tap the oil seal into place until it seats.
NOTE
You may find that a piece of pipe just
large enough to slide over the fork tube
will seat the oil seal squarely without
damaging it (Figure 17). Make sure the
seal is not cocked in its hole.
6. On models with an oil seal retaining clip
with notches on the inside (Figure lo), install
the oil seal circlip.
7. Install the dust cap.
8. Add fresh oil to each fork tube; see Fork Oil
Change in Chapter Three.
9. Install the fork spring and install the top
plug (Figure 18).
NOTE
If one end of the fork spring has more
closely wound coils than the other end,
install the spring with the closely wound
coils at the top.
10. Push the top plug into the fork tube and
hold it in place while you install the circlip
(Figure 19).
1 1 . Models with air pressurized forks,
pressurize them. See Fork Air Pressure in
Chapter Three.
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   Also See for Kawasaki KZ500

This manual is also suitable for:

Zx550Kz550Kzx550

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