Z1OwnersClub GB

How do you remove the recessed allen bolt from the fork leg.
I went for my first ride tonight after bringing my bike back from the dead and registering it, to Matlock bath and noticed that one of the fork seals was leaking.
I cannot seem to undo the bolt, it was very tight to start and now both are still quite tight but keep going around with nothing happening. This is with the forks legs still in the yokes.
I've not done forks before, am I missing something?
I've now taken the tops off and removed the springs and taken the fork out of the yokes, I presume I need to seperate the legs from stanchions so I can replace the seals.
Help

I suspect we've all been down this road!

Kawasaki have a special tool that goes down inside the leg to hold the internal gubbins while you undo the allen bolt.

Or, if you put it all back together and find somebody with a "rattle gun", the sort of thing that Fastfit mechanics take your car wheels off with. Together with an allen key attachment, that should shift it!

To be honest though, with care, now you have the fork out of the yolks, you could change the seal without dismantling the leg. Just don't dig around the seal too much because the soft aluminium recess is easily damaged!

Good Luck

Mark

This may help





Its all the 3/8 drive extensions i had and the last one is just the 3/8 inch drive end with nothing on it.

AL

no need to seperate forks to do seals ... just remove clip off seal and prize the seal out with a screwdriver

Thanks for those suggestions, I'll let you know how I go on.

Zorded, I see whe have a vice in common

impact gun whips it out no problem

A whittled down broom handle works OK

Pigford wrote:A whittled down broom handle works OK

That would easily win you another set of spanners

That is what I used as well .

pignog wrote:Thanks for those suggestions, I'll let you know how I go on.

Zorded, I see whe have a vice in common

You collect socket extension bars too?

No same Record vice

I've used a brush shaft myself often on other forks!!

Jimmock.

I used a poker from a coal fire.... ......but it worked a treat.

I've tried socket extensions, rattle gun and broom handle with no avail
So i have chisellead the old seals out with a.....chisel and screwdriver
lets hope that works

If you contact Jerry he will lend you the Club fork spanner.
I used it, I also got a local engineer to make me one.

I made this up out of a length of tube and a machine mart punch