KZ650 D3 SR Front Forks - Kawasaki Motorcycle Forums
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post #1 of 11 (permalink) Old 04-04-2019, 09:15 AM Thread Starter
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KZ650 D3 SR Front Forks

Having rebuilt front forks i am know finding that the forks top out, Have no sag in at all, Pull down on bars and bang straight back up.
(topped out) any help please.

Regards

Trevor.
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post #2 of 11 (permalink) Old 04-04-2019, 06:26 PM
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It would help greatly if people asking questions provided more information.
I have no idea why you rebuilt the forks nor what you consider a rebuild. So I will make some assumptions.
1- you completely disassembled the forks
2-you do not have a great deal of experience in fork repair
After you removed the fork cap and spring you would have removed the fork dust seal and the fork oil seal retaining clip. Next would be the removal of the damper rod retaining Allen blot and gasket. This would allow you to pull the fork slider off the fork tube leaving the damper rod with the spacer/sleeve on the tapered end of the rod. After removing the sleeve you would either use a dowel to push the damper rod out the top of the fork or turned the fork tube upside down and tapped on a piece of wood to slide the damper rod out. You should have seen a spring under the piston of the damper rod, this is the top out spring. If this spring was missing or if you installed it on top of the damper rod you would not have any spring cushion in a top out situation. If this rebuild was to also install after market springs you would be required to make some calculations to determine preload spacer length. If this was the case perhaps you made an error and cut the preload spacer to long. How did you set fork oil level?
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post #3 of 11 (permalink) Old 04-05-2019, 12:05 AM
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Did you put the right amount of oil back in? Was it the right weight?
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post #4 of 11 (permalink) Old 04-05-2019, 04:42 AM Thread Starter
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Hi
Forks do not have preload spacers, Has progressive springs in so have put tighter coils to the top on both forks.
10w oil, correct amount of oil per leg as from a manual, and air gap,small spring is on bottom of damper rod.
The only issue i have is can you fit the spacer right at the bottom with sleeve around the wrong way and would it cause this problem.
all help greatly appreciated.

Thanks

Trev the rev.
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post #5 of 11 (permalink) Old 04-05-2019, 03:39 PM
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Why did you rebuild the forks? what did you do?
Was this problem there before the rebuild?
Are the fork springs new, or new the this motorcycle?
Typically that spacer is somewhat cone shaped and slides over the end of the damper rod. If that is the type you have, and most older forks were made that way, I don't think you could put it in upside down. I don't think the damper rod bolt would be any where long enough to reach the damper rod with the spacer in upside down.
You say you have no sag and the fork tops out, if the spring is new perhaps it is the wrong one, much to stiff, and just overwhelms the damping force and top out springs.
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post #6 of 11 (permalink) Old 04-06-2019, 08:51 PM
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Are the springs Progressive brand? And are they the correct length. The D3 SR may not have a spacer above the stock fork springs, but the Progressive brand springs may need a spacer.

As for the spacer at the bottom >> I can't imagine anyone installing that wrong.



...

1981 KZ650-CSR. Competition, Sports & Road.
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post #7 of 11 (permalink) Old 04-07-2019, 07:09 AM Thread Starter
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Yes they are progressive with coil bound at top, do not know want length of spring should be and only putting a space in would compress the springs more making the issue worse.


Trevor.
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post #8 of 11 (permalink) Old 04-07-2019, 10:52 AM
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Just trying to clarify what you have. Are they aftermarket Progressive-brand springs or the stock springs?
The stock springs are progressive-type of springs >> the coils are wound tighter on one end than the other.
Progressive-brand springs are sometimes too short for the application, so Progressive says to add a spacer >> the Progressive-brand spring w spacer should be the same length as the stock springs.
There should be spring pressure on the fork caps when you install the caps. My forks have spacers which protrude about an inch above the fork tube prior to installing the caps. Also, make sure the short rebound spring is installed correctly.

....

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post #9 of 11 (permalink) Old 04-08-2019, 03:24 AM Thread Starter
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Top out spring on damper rod is correct,i also have around 10mm of spring to push down when installing the top caps.Does anyone know the correct length of springs.

Trevor.
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post #10 of 11 (permalink) Old 04-09-2019, 12:40 PM
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kz650 d3 sr front forks

Trev,the Fork Spring free Length,service limit is 521.5mm.Hope this helps.
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