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Kawasaki Gpz 1100 B2 Service Manual Free
Kawasaki Gpz 1100 B2 Workshop Manual

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GPz 1100 B2 - front fork disassembly??? 24 Apr 2016 12:51 #722701

OnkelB
Topic Author
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Posts: 1011
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So I'm in the process of replacing my fork oil seals as one is leaking. Fork legs are off, top caps, dust caps and retainer rings are removed, so far so good.
But how the %@$* do you remove these plugs (pic below) from the top of the leg? According to my manuals (FSM and Clymer) they're unique to the B-models, should have an o-ring on them and the manuals just say to remove them. Yeah right, problem is they won't budge no matter what I try.
Decided to step back before I messed something up, but what am I missing? Is there a trick I don't know or a special tool I don't have? Any advice is much appreciated. Thanks

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GPz 1100 B2 - front fork disassembly??? 24 Apr 2016 14:32 #722713

Mcdroid
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Gone Kwackers
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It has been a while since I did my GPz1100 front end, but if I recall correctly, I used either a 1/2 inch or 3/8 inch ratchet (with a small same sized extension) as the square end fits perfectly into the square depression in the top of the plug.

Michael
Alvin, Texas
1982 GPz750
1977 KZ1000A
1978 KZ1000A
1982 GPz1100
1975 Z2A

GPz 1100 B2 - front fork disassembly??? 24 Apr 2016 15:38 #722726

OnkelB
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So they're threaded in? I suspected as much as I noticed that a 1/2' extension square fits perfectly in the plugs. Thing is the inner tubes are damn near perfect, not a mark on them and I'd like to keep them that way - couldn't get a firm enough grip on the tubes in my vice (with protection) to keep them from spinning trying to break the plugs free and had to stop in fear of scoring the tubes, I'll bring them to work tomorrow and see if some heat and an impact gun will help. Thanks.
Edit: Oh hey, 1000 posts!!! Only took me 13 years, guess I need to get out more..

GPz 1100 B2 - front fork disassembly??? 24 Apr 2016 16:07 #722736

SWest
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Yeah a little heat and a grip where the headlight ears are should get them to budge. If you mark them there, no one will see it. Just don't clamp where the cap is.
Steve

Z1b1000 1975 Z1b
Opinions expressed by me do not reflect those of the the staff or members
kzrider.com/forum/11-projects/598262-kz-..-will-it-live#672882
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GPz 1100 B2 - front fork disassembly??? 24 Apr 2016 17:41 #722768

rinferno
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Posts: 45
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Ditto as everyone else has said, 1/2' drive extension. Make sure there is no tension on your fork leg, otherwise the fitting will fly out, once loose. I just changed the fork oil on my 82 gpz 750 looks identical.

The following user(s) said Thank You: OnkelB

GPz 1100 B2 - front fork disassembly??? 25 Apr 2016 04:47 #722822

GPZ1100_Rider
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Just a suggestion, but you might want to consider replacing the front springs with aftermarket ones, that are tailored to your weight and riding style. I changed out mine with this company's Sonic Springs and it made a big difference in ride, dive when applying front brakes, and general handling when compared to the softer stock ones. I went with good brand of 15W fork oil too.

GPz 1100 B2 - front fork disassembly??? 25 Apr 2016 06:12 #722835

Kawasaki Gpz 1100 B2 Service Manual Free

martin_csr
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I used a spare triple tree as a clamping device & applied heat using a propane torch. some penetrant wouldn't hurt either. Kroil is supposed to be best, but I use Liquid wrench penetrating spray lubricant. it's readily available & cheap (USA). not sure what's available in Europe.

The following user(s) said Thank You: OnkelB

GPz 1100 B2 - front fork disassembly??? 25 Apr 2016 07:53 #722856

OnkelB
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Posts: 1011
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Well, got it sorted - as always it was a matter of the right tool for the job.
Brought the legs with me to work today and set them up to soak in penetrant all day. After work I stuck them in a big vice and applied our electric impact gun, didn't work. Then tried a 1/2' extension with a breaker bar, didn't work either, the legs just spun in the vice.
Gave up and took the legs to the nearest bike shop, literally 6 houses from where I work - his air gun broke them loose in a matter of minutes, didn't even charge me.
Thanks to all that replied.

GPz 1100 B2 - front fork disassembly??? 26 Apr 2016 10:37 #723070

OnkelB
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Posts: 1011
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So I got the forks apart and ran into another issue - got to love previous owners .
The B2 has two springs (rebound springs?) on the damper rod, a thin and a thick, but which one goes where? The problem is that when I took the forks apart one came out like pic A below, and one came out like pic B - I can't find any info or pics in any of my manuals and the parts diagram is too blurry to determine which spring is which. Does anyone know which way is correct?

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GPz 1100 B2 - front fork disassembly??? 26 Apr 2016 11:55 #723087

Mcdroid
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Gone Kwackers
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