Front fork question

[Hillbilly]

Hi everyone, I was doing an oil and seal change on my forks, and when I drove out the old seal to remove the inner barrel of the fork the end of the valving where the bolt goes into the bottom of the fork came out so I couldn't tell what went where. I'm hoping you guys would know. I looked at the download from the manual but it didn't seem right and kind of hard to tell how it sets on the end of the unit inside the fork.

Thanks for the help

[ghostler]

It's been a while since I disassembled both forks and replaced the seal, dust cover and spring with Progressive Springs. I think the threaded end that you show was held in place at the bottom of the strut by a single Allen socket head bolt in the center bottom of the strut.

The manual, Page 12-7 shows a Front Fork Cylinder Removal drawing.

Front Fork Cylinder Removal Diagram

The following is from my parts manual, Page 65 for the 2001 (B15) model. As far as I know, the parts are the same for years 1987 to 2003.

Front Fork Parts Diagram

Front Fork Parts Descriptions

Hopefully these will give you a clue onto what parts go where and how they interface. For easier viewing, you may want to right click after opening the attachment, and do a save image as to your hard disk. Then use your photo viewer to zoom in for a better look.

[triton28]

This parts illustration from a 1987 catalog has a good view of the "hat shaped" shouldered washer and spring orientation.
https://www.partzilla.com/catalog/kawas ... front-fork

[VoyKimmer]

Here is a good video instruction.

[Hillbilly]

Thanks everyone, I knew I could count on you

[Hillbilly]

Voykimmer,I didn't get the link to the video you suggested
Could you try again... I would like to see it. Thanks

[VoyKimmer]

It’s not a link it’s a file that won’t upload. It’s a video of Carl Leo doing a demonstration at the Santa Fe Rally. Not sure why it doesn’t upload. Probably to big of a file size.

[Bonnie and Clyde]

Out of curiosity can you remove the forks without taking the fairing off? I know the manual says to take the fairing off. I was hoping to just take the front wheel and fender?

[HMB Don]

Short answer YES.

[Nails]

But after the 73rd time or so, the fairing practically jumps off anyway.

[VoyKimmer]

[Bonnie and Clyde]

Short answer YES.

But the long answer is?

[GrandpaDenny]

Short answer YES.

But the long answer is?

Still yes. No need to take the fairing off at all. I think maybe the service manual's recommendation to remove the fairing for some procedures is to keep from potentially damaging the fairing rather than it actually being in the way.

[Bonnie and Clyde]

Short answer YES.

But the long answer is?

Still yes. No need to take the fairing off at all. I think maybe the service manual's recommendation to remove the fairing for some procedures is to keep from potentially damaging the fairing rather than it actually being in the way.

It looks like the triple tree bolts are easy enough to access with the fairing in place. I was unsure about the suspension air tube thingy mentioned in the manual. Thanks for the response

[Nails]

It looks like the triple tree bolts are easy enough to access with the fairing in place. I was unsure about the suspension air tube thingy mentioned in the manual. Thanks for the response

Do you really even have to remove the fork tubes for the work you plan?

[Bonnie and Clyde]

It looks like the triple tree bolts are easy enough to access with the fairing in place. I was unsure about the suspension air tube thingy mentioned in the manual. Thanks for the response

Do you really even have to remove the fork tubes for the work you plan?

Doing fork seals

[Nails]

Doing fork seals

I have a good local independent shop and just took my forks off the bike, rounded up the parts, and took them down for Progressives, bushings, and seals. I didn't feel like messing with it when they have the right setup, and I don't mind throwing some work their way. So I don't really know what I'm talking about here, but I believe you can get the fork legs off and all disassembled without taking the tubes out of the triple clamps. Barry uses long clamps that fit right down through the fairing to pull his springs and change the oil. (That's on this fall's maintenance list.)

[Bonnie and Clyde]

Doing fork seals

I have a good local independent shop and just took my forks off the bike, rounded up the parts, and took them down for Progressives, bushings, and seals. I didn't feel like messing with it when they have the right setup, and I don't mind throwing some work their way. So I don't really know what I'm talking about here, but I believe you can get the fork legs off and all disassembled without taking the tubes out of the triple clamps. Barry uses long clamps that fit right down through the fairing to pull his springs and change the oil. (That's on this fall's maintenance list.)

Leaving the tubes in the triples would be slick thanks

[Heavy Armor]

I'm hoping to get my forks off without removing the fairing also, and take them to a shop for rebuilding and a progressive spring upgrade. I did it myself on my Triumph, and what a mess. I have no desire to tackle that again.

[GrandpaDenny]

It looks like the triple tree bolts are easy enough to access with the fairing in place. I was unsure about the suspension air tube thingy mentioned in the manual. Thanks for the response

The air tube stays in place, there are collars that go around the fork. When pulling the forks, you have to hold on to the air tube collars to keep from pulling them down and breaking them. This is what makes a second person handy when pulling (and reinstalling) forks - someone to hold the tubes.