1983 KZ440 front fork oil change - Kawasaki Motorcycle Forums
 
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post #1 of 5 (permalink) Old 04-20-2017, 10:46 PM Thread Starter
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1983 KZ440 front fork oil change

This is my first street motorcycle. I bought it a few month back and want it in proper condition before the season really kicks off. As part of that I wanted to change the front fork oil because I don't know when the last time it was changed. According to my owners manual I am supposed to remove the drain bolt, (did that, sprayed high pressure oil all over myself and garage, lol) then slide the forks up and down to pump out the rest of the oil (did that) then remove the filler cap from the top of the fork. (20170420_205228 ) I removed the black cap from the top and discovered (20170420_205246) I removed it and (20170420_204857) other angle (20170420_204906), I tried unscrewing what I thought was the filler cap I was supposed to be removing but all it does is spin, so with some ingenuity I made a valve core remover to pull out the air valve (20170420_204746) after trying unsuccessfully to get oil through that hole I removed the forks entirely. With the idea that if I tried disassembling the forks I could fix the issue. Same problem, still cannot get what I think is the filler cap to come off to change the oil. Any help with how I am supposed to take this thing apart? The disassembly part of the shop manual's first step is too take off the filler cap and take out the spring. There is this (20170420_204921) at the bottom of the fork and the disassembly portion says to insert an Allen wrench into the bottom. But the problem of the filler cap still remains. Advice and any help is greatly appreciated. Thanks.
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File Type: jpg 20170420_205228[1].jpg (91.6 KB, 1 views)
File Type: jpg 20170420_205246[1].jpg (96.6 KB, 2 views)

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post #2 of 5 (permalink) Old 04-21-2017, 10:25 AM
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There's probably a circlip or snap ring that needs to be removed. You have to push down on the fork cap, then pry out the clip. You may need a helper. Keep in mind that the cap is under spring pressure, so when the clip is removed the cap can go flying & hit you in the head or your eye.

At partzilla. 1983 KZ440-A4. diagram reference #92033. 44044-023 CIRCLIP. (no drawing).
There's also a snap ring listed. 92033A --- 92033-1070, but without the diagram drawing, I don't know where the snap ring goes. It may be that your bike has the snap ring & an earlier model or models have the circlip. not sure. ???


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1981 KZ650-CSR. Competition, Sports & Road.
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post #3 of 5 (permalink) Old Yesterday, 08:20 AM Thread Starter
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After looking at the diagram online for the bike it appears that there is a circlip and a snap ring. the circlip is on the top of the fork with the filler cap and the snap ring is under the dust boot. Ill see what I can do with them, thank you!

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post #4 of 5 (permalink) Old Yesterday, 10:24 AM Thread Starter
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So I dug around in one of the caps and this is what I found, there is a little gap in what I think is the snap ring but I have no idea how to remove it. Side note, I should probably replace the spring seat given all the rust on it?
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post #5 of 5 (permalink) Old Yesterday, 05:04 PM
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Can you push down on the caps?

To dig out the circlip a carpenter's awl might work.
There should be an gap in the circlip where you would pry the thing out.





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