Forking Problems

[bollypne]

I am trying to remove the fork leg inners from the forks on my Z900. The allen bolt in lower leg just seems to turn with no effect, Haynes manual seems to suggest it just unscrews and hey presto the stancion pulls out!
Any advice greatly appreciated. Thanks.

[rickman CRR]

kawasaki offer a special tool which holds the internal nut. The Club has special tools available for members to borrow. I dont know if this tool is available, perhaps Jerry can advise.

I have in the past used a long shafted screw driver to lock the internal nut.

[phil churchett]

:? I am trying to remove the fork leg inners from the forks on my Z900. The allen bolt in lower leg just seems to turn with no effect, Haynes manual seems to suggest it just unscrews and hey presto the stancion pulls out!
Any advice greatly appreciated. Thanks.

Yes, the Haynes manual strikes again!
Try and get yourself a genuine manual, or at least a Clymer, they are far superior.

[mikey]

This may sound bit radical but it works everytime for for me,
get a broom handle sharpen the end put sharp end down the
stanchion couple taps on the end of the broom handle till its wedged
and itll hold it while you undo the allen bolt, an old guy showed me that
trick many years ago (god rest his soul) when he died at the age of 82
he was still riding.

[steve f]

had the same problem last weekend with some kh500 forks which are the same forks i am informed can anybody clarify this ????

[davy thomson]

If hae had this problem in the past with most forks. If you know of a good welder get the size allen bolt size and weld a bolt to a lenth of 12mm round bar then weld a bit of bar to form a T bar insert and hey presto you have a tool for the job works every time for me and also aids the rebuild.

[phil churchett]

Good tip Davy, but Mikeys takes the biscuit!
Must try and remember that one.

[mikey]

Yes phil after you broom handled your forks you sit
back relax have cup of tea and take a biscuit.

[Pasc]

I've used both Mikeys and Davy's method in the past on several fork rebuilds with good results ( Fork rebuilds are a pet hate of mine). I prefer Davy's method as the tool can then be kept on the shelf for future use whereas the broom handle eventually goes smooth and oily on the business end and loses its grip.
Another method I've heard of but not used is the power ratchet similar to what tyre fitters use to do up / undo your wheel nuts but I think if you use one of these on bolts that have already been loosened you will just end up spinning the damper tube.
I think Machine Mart sell a fairly inexpensive power ratchet that is up to the job.

[mikey]

And the mrs aint to impressed when she gets fork oil all
over her hands next time she sweeps the floor

[phil churchett]

Yes phil after you broom handled your forks you sit
back relax have cup of tea and take a biscuit.

Custard Cream sir?

[mikey]

Oh no only the best for me phil chocolate coverd hob nobs Mmmmmm!!!!!!

[bollypne]

Cheers all, now anyone in the Chorley or Bury area with a tool i can borrow.

[bollypne]

Thanks to all that replied, well the broom handle method worked. As the bold head down inside the fork is unusual it was the only method. The bolt head is basically round with 2 flat sides only. I shall be trying to fabricat some kind of tool to aid putting bak together. Cheers.