Quote:
Originally Posted by BlackFrost
let us know how that turns out...gonna re valve the forks on my 95 zx11d...good luck...
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Make sure you have the tool on hand to loosen the allen bolt from the piston. I didn't, and had to take mine to a dealer to loosen; one leg loosened fine, the other, he said, was difficult. Both allen bolts had factory threadlocker on them, and they had never been off until now.
Once apart, I made a tool to tighten them [calls for 29 ft lbs torque]. The top of the piston [Kaw calls this "fork cylinder" - #44022] has a 12 pt socket configuration, so some sort of hex-head tool was needed to hold piston while tightening allen bolt. My tool inexpensive and easy to make: I took my piston and my dial calipers to Lowes and found a pipe fitting reducer bushing with a hex that almost fit into the piston hex - the bushing is a 3/4 X 1/4 reducer, and its hex measured 1.160" across flats - I needed 1.152", and a little dressing with a file made the perfect fit; next, I re-tapped the 1/4 NPT hole in the reducer to a 1/2-13, and screwed a 1/2" socket head cap screw into it, lock-tited it, with a jam nut on each side. Now I can reach down onto the fork tubes with a two foot extension [w/ a 3/8" allen socket] and hold the piston while tightening. The reducer bushing was a little over a buck, and the 1/2"shcs [2"long] I had on hand. My 3/8" drive extension is 24" long.
Hope this helps anyone contemplating disassembly of their forks [at least the C model].
Dick
