Another fork disassembly thread - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 8 (permalink) Old 03-02-2018, 12:28 AM Thread Starter
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So I swapped forks on my bike and Iím going to rebuild my old ones I took the dust seal off I took the spring and tube out of the top with the cap/ retaining clip. now after removing the C clip from under the bottom dustcover I am trying to pull the oil seal. I have gone as far as the stick a 2 foot piece of rebar through the bottom and vice clamp the top pulling hard enough to move my table and I still cannot get it to release so the question is any tricks that I should know?

Ps- is it aluminum? If so Iíll hit it with a torch.


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post #2 of 8 (permalink) Old 03-02-2018, 08:05 AM
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probably just stuck/rusted into place.

on mine, after I had it apart as far as you do, I just held the inner tube (top), and a few quick pulls of it and it slid right out. I was using it like a slide hammer. didnt even have it clamped in a vice or other method to hold it, just in my 2 grubby mitts

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post #3 of 8 (permalink) Old 03-02-2018, 08:09 AM
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The only aluminum is the lower fork.

Might need to pry around the seal enough to deform it some and pull it away from the edge.

If you could get the bottom allen bolt removed, the upper fork tube then acts like a puller and the seal will pop right out without having to pry on the seal at all. But the seal can be picked out from the top with picks, small screwdrivers, etc.

Heat will loosen the threadlocker on the bottom allen bolt, but the oil has to be drained first.

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post #4 of 8 (permalink) Old 03-02-2018, 08:16 AM
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If I understand ... You have the rebar through the axle hole and pulling with it? Upper tube clamped in a vise?

The bottom allen bolt is holding it together.

2003-21k mi
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__________________________________________________ ____________
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post #5 of 8 (permalink) Old 03-02-2018, 11:16 AM
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oh yea, the bottom bolt has to be out..

and my memory has returned on how I did mine..

spring and such out of the top tube
bottom bolt out and oil drained
dust boot and c clip removed
with top tube still in the triple tree, grabbed the lower and rammed it downward, seal popped right out

2005 VN750

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post #6 of 8 (permalink) Old 03-02-2018, 11:46 AM
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And that oil is unholy putrid! Whale oil?

2003-21k mi
Shaved w/UniPK92+Stock Jets-TPE/MOSFET-Shinko Tires-AGM batt-bags-chrome-LEDs...more
__________________________________________________ ____________
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Owner's Manual: http://www.mediafire.com/file/nscb5f...ers+Manual.pdf
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post #7 of 8 (permalink) Old 03-02-2018, 12:18 PM Thread Starter
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That would be what i was unclear on. If the allen bolt held the upper shaft seal somehow. I donít see how it does it after seeing the seal out, but thatís the ticket i guess.


1981 KZ750
1988 Vulcan VN750 (red)
2005 Vulcan VN750 (silver)
(2) 1994 Vulcan VN750 (red)

Engineering solutions for the VN750 Community.
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post #8 of 8 (permalink) Old 03-02-2018, 12:54 PM
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That ported valve cylinder is what the allen bolt threads in to. The fitting on the base of the upper fork is either tapered or shouldered, , so when it's bolted together, the valve block is wedged into the bottom fitting of the upper leg.

This is a good video, but the first thing to do is try and break that allen bolt loose while everything is on the bike. He makes a note of that about mid-video.

Also note the alignment of the split in the bushing at 8:00, split aligns to the left or right, versus front/back. ... and..., note the 9" oil height measurement after filling and bleeding.


2003-21k mi
Shaved w/UniPK92+Stock Jets-TPE/MOSFET-Shinko Tires-AGM batt-bags-chrome-LEDs...more
__________________________________________________ ____________
Repair Manual: http://www.mediafire.com/file/mj7z81..._Catalogue.pdf

Owner's Manual: http://www.mediafire.com/file/nscb5f...ers+Manual.pdf

Last edited by Spockster; 03-02-2018 at 01:12 PM.
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