Question about 1991 kawasaki ZZR 250

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Front fork bolt wont tighten - 1991 kawasaki ZZR 250

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6ya6ya
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SOURCE: I have freestanding Series 8 dishwasher. Lately during the filling cycle water hammer is occurring. How can this be resolved

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Posted on Jan 02, 2017

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cape cod bob
  • 292 Answers

SOURCE: KX125 Front Wheel assembly

you are missing a spacer

try here for exploded views
http://www.babbittsonline.com/pages/parts/viewbybrand/1/Yamaha.aspx

Posted on Apr 12, 2009

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1 Answer

98 W/Glide forks out of alignment how do I straighten them?


Hi, Max if your front forks are only twisted and not bent they can be realigned, start by jacking the bike up so the front wheel is off the ground; a half-inch or so will do it.
If the forks have been removed from the bike:
1. Set the fork height in the upper clamp, and then tighten the pinch bolts in 3 equal stages to the proper torque. If you're not convinced that the heights are equal, slip the axle into place. If it doesn't glide smoothly through the forks, one leg is higher than the other, so readjust them until the axle slides through them with little or no effort.
2. Install the front fender but don't tighten the bolts.
3. Install the front wheel and axle. If the axle threads into the fork, thread it in loosely, if it uses a nut, just snug the nut down by hand. Do not tighten the axle pinch bolts.
4. Spin the wheel as fast as you can and abruptly pull on the brake lever. Holding the brake lever on, tighten the front axle.
5. Lower the bike onto the ground, and, while holding the front brake, gently pump the forks a few times. You did remember to tighten those upper pinch bolts, didn't you?
6. Tighten the lower clamp's pinch bolts in 3 equal stages, followed by the axle pinch bolts to the proper torque.
7. Tighten and torque the fender bolts.
If you suspect the forks are tweaked but don't want to go through the procedure above there is an easier way.
A. Support the weight of the bike on the jack or center stand, and loosen the front axle.
B. Remove the lock nut, and then try to slide the axle out of the fork. If it comes away with little effort, the forks are in alignment. If the axle has to be pounded out, it's a safe bet the forks are slightly tweaked or rusted.
C. To correct a slight misalignment, loosen everything but the top clamp pinch bolts (you don't have to remove anything), and start at Step #3. Anytime the wheel is removed, perform steps #4 and #5: that'll center the wheel in the fork and provide better suspension and braking action.
If your forks are aligned but your handlebars are twisted start by loosening the handlebar clamp bolts, then in a criss-cross pattern tighten the bolts in 3 equal stages to the proper torque. You will see that tightening a specific corner pulls the handle bar in a specific direction you can loosen and tighten the bolts on one clamp to achieve proper eyeball alignment, it may take a few attempts to get the desired results.
For more information about your issue and valuable "FREE" downloads that you will need please click on the links below and for more specific information or questions at no charge please feel free to contact me at xlch@mail.com. Good luck and have a nice day.
Harley Davidson Manuals Mark Workshop
http://partsfinder.onlinemicrofiche.com/stcharlesharleydavidson/showmodel.asp?make=hdmc
https://serviceinfo.harley-davidson.com/sip/vehicle/lookupForm
Instant Tech Relief A must have !!! Absolutely Totally "FREE"

Nov 01, 2016 | Harley Davidson FXDWG Dyna Wide Glide...

1 Answer

What socket do i need for removing the caliper bolts on a 2005 road king custom


The bolts are metric and use a 10mm 12 point head.
To re-install caliper:
1, Loosely install long caliper mounting bolt into upper
lug of front fork leg.
2, Install short caliper mounting bolt into lower lug of
front fork leg. Tighten lower mounting bolt to 28-38
ft-lbs (37.9-51.5 Nm).
3, Tighten upper caliper mounting bolt to 28-38 ft-lbs
(37.9-51.5 Nm).
4, Tighten pad pins to 180-200 in-lbs (20.3-22.6 Nm).

May 03, 2014 | 2005 Harley Davidson FLHRS - FLHRSI Road...

1 Answer

1999 harley roadking rear and front axle torque specs??


Use loctite on the threads of all parts. For the front, holding the axle with a tool in the hole, tighten the axle nut to 50 lbs.

If your bike has dual front disk brakes, you need to insert a 7/16 drill bit into the hole in the axle. This step is necessary to give the proper spacing to the brake discs. Loosen the pinch bolt at the bottom of the fork. Move the fork so the drill bit rests snugly against the side of the fork. Now tighten the pinch bolt making certain the drill bit still contacts the side of the fork.The pinch bolt should get not more than 30lbs.

for the rear, the axle gets 60 lbs. If you loosened the shocks to make room for the wheel tighten those bolts to 35lbs.

I sure hope you kept all the spacers and washers in their correct positions.

Here's hoping that gets you back on the road.

Ride safe, ride longer.

May 11, 2011 | Harley Davidson FLHRCI Road King Classic...

1 Answer

How do I put front wheel on without making the forks lock up it keeps doing that when I put it on my02 cr250


Putting uneven loading on the forks(twist) may cause binding and harsh action but I haven't heard of them locking up. Try the following order of installation. position the wheel and slide in the axel. Tighten the axel, leaving the pinch nuts loose. Spin the tire and stop it a few times using the front brake. Tighten the pinch nuts. Put bike on the ground and see if forks still bind. If they do then loosen the pinch bolts, lock the front brake and try to compress the forks. This should align the forks. Tighten the pinch bolts. Check forks again. If you still have problems someting is wrong like bent fork tube or slider, misaligned triple clamp, maybe a bent axel.You might take off the fork tubes and push on them seperately to make sure they feel ok. Then do the install checking the forks at each step to find the place where binding starts. Good luck.

Feb 20, 2011 | 2002 Honda CR 250 R

1 Answer

How much fork oil goes in the forks of an 2001 FXD and how do I do this ? Do you have any diagrams to help me with ?




I have no diagrams for you. MAke your own as you take it apart etc and take lots of cell phone pictures if you need help remembering how to put things back together.

Table 1-6. Type E Fork Oil Amounts



MODEL OZ CC IN. MM



FXDXT 11.5 341 6.10 154.9



FXDWG 12.0 356 7.28 184.9



FXDL 10.7 316 7.20 182.9



FXD 10.6 314 6.69 169.9




Changing fork oil is a simple mater for some models and requires fork disassembly for others. Here is the procedure for all 2001 DYNA models:

2001 DYNA FRONT FORK OIL 1.18


REPLACING FORK OIL Replace front fork oil at every 20,000 mile (32,000 km) service interval and/or prior to storage.


ALL BUT FXDX & FXDXT models


Raise and support the motorcycle so the front end is off the floor and the forks are fully extended, on FXDL models, remove the center plug from each fork cap, on all other models, remove the fork tube caps, remove the drain screws from the bottom of each fork and drain the fork oil, replace the drain screws and washers and tighten the screws

to 13-17 in-lbs (1.5-2.0 Nm) THEN see Table 1-6. and fill the fork with Harley-Davidson TYPE E FORK OIL (Part No. HD-99884-80) as set out in the Table. THEN if apart assemble the forks as follows:


a. FXD, FXDXT, FXDWG models: install both fork tube caps and tighten them to 11-22 ft-lbs (14.9-29.8 Nm).

b. FXDL models: install center plugs and tighten until secure.


Fork oil amounts can be measured two ways: use the oz./cc measurement if fork is left in frame; use the in./mm measurement if the fork is disassembled in which case the oil level is measured from the top of the fork tube with the spring removed and the fork fully compressed.


Table 1-6. Type E Fork Oil Amounts for 2001 DYNA


MODEL OZ CC IN. MM

FXDXT 11.5 341 6.10 154.9

FXDWG 12.0 356 7.28 182.9

FXD 10.6 314 6.69 169.9


PART NO. SPECIALTY TOOL

HD-41177 Fork tube holder

HD-41549A Fork spring compression tool

HD-41551 Spring plate tool

HD-36583 Fork seal installer

HD-59000A Pro-level oil gauge



FRONT FORKS: FXDX & FXDXT 2.20

REMOVAL

Raise and support the motorcycle so the front end is off the floor and the forks are fully extended, remove both front brake calipers and the front wheel, remove the front fender, remove the front fairing, remove the headlamp bracket and attach the headlamp to the frame using a rubber bungee strap, loosen the upper and lower triple clamp pinch bolts and pull the fork sides from the brackets.


DISASSEMBLY

Remove the stopper ring, remove the spring preload adjuster but DO NOT unthread the rebound adjuster from the damper rod because incorrect assembly could result in reduced adjustment range. THEN unthread the fork cap from the fork tube and allow the fork leg to drop, exposing the spring, THEN get a FORK SPRING COMPRESSION TOOL (Part No. HD-41549A) on the spring collar, turn the screws in to engage the holes in collar, compress the spring until the SPRING PLATE TOOL (Part No. HD-

41551) can be positioned between the spacer and the spring collar, THEN hold the fork bolt and compression adjuster, remove the fork bolt from the compression adjuster, remove the spring adjuster plate from the fork bolt, remove spacer, spring collar and spring, pour out the fork oil by pumping the fork leg and rod 8-10 times or until rod the moves freely. THEN position fork slider in vise using a FORK TUBE HOLDER such as (Part No. HD-41177) to avoid damage. THEN remove the socket head bolt, remove the damper from the fork tube, remove the cover from the slider, remove seal and stopper ring, pull the fork tube out of the slider, remove the oil seal, spacer and guide bushing from the fork tube.


CLEANING AND INSPECTION

Measure the fork spring free length and replace the spring if it is shorter than 17.00 in. (431.8 mm), check the fork tube and the slider for score marks, scratches or abnormal wear, check the slide and guide bushings for excessive wear or scratches, set the fork tube on V-blocks and measure runout which should not exceed 0.008 in. (0.2 mm).


ASSEMBLY

Coat the oil seal with TYPE E FORK OIL, before installing the slide bushing and guide bushing, lubricate them with fork oil, THEN install the guide bushing and the spacer seal noting that the guide bushing opening must be oriented to the side and NOT to the front or rear, THEN slip the slider into the fork tube, place the slide bushing over the fork tube until it rests on the slider, drive the guide bushing with the spacer seal into the slider, lubricate a new oil seal with TYPE E FORK Oil, drive the oil seal into the slider using FORK SEAL INSTALLER (Part No. HD-36583). install the stopper ring and dust seal, (if the rebound adjuster was removed from the damper rod bottom the lock nut on the threaded portion of damper rod, holding a thumb on the detent spring and ball, back out (turn counterclockwise) the rebound adjuster to the last "click." and then turn down (clockwise) 17 "clicks", thread the rebound adjuster onto the damper rod until the adjuster stops at maximum thread engagement (but do not force it), thread the locknut onto the damper rod up until it contacts the base of the rebound adjuster and tighten it in place), THEN holding the slider in a vise while being careful not to damage it. install the damper tube into the fork tube and tighten the socket screw and washer to 22-29 ft-lbs (29.8-39.3 Nm). THEN pour half the TYPE E FORK OIL into the fork tube, slowly pump the damper rod 10 or more times, position the damper rod in the fully bottomed position and pour the remaining amount of TYPE E FORK OIL into the fork tube. THEN using a PRO-LEVEL OIL GAUGE (Part No. HD-59000A) or similar adjust the oil level to 5.04 in. (128 mm). THEN carefully clean and install the spring, the spring collar, and the spacers with the sharp edge created when they were stamped out when manufactured, facing the collar. THEN using a FORK SPRING COMPRESSION TOOL such as (Part No. HD-41549A) push spring collar down and place a SPRING PLATE such as (Part No. HD-41551) between the spacer and the spring collar, install the fork cap and tighten it against the rebound adjuster to 22-29 ft-lbs (29.8-39.3 Nm). THEN tighten the fork cap onto the fork tube to 11-22 ft-lbs (14.9-29.8 Nm), install the spring adjuster plate, replace the O-rings on the spring preload adjuster and lubricate them with fork oil. THEN install the spring preload adjuster and the stopper ring and carefully drive the slider cover into the slider.


INSTALLATION

Insert both fork side assemblies up through the fork stem and bracket and upper bracket and tighten the fork stem bracket pinch bolt(s) to 30-35 ft-lbs (40.7-47.5 Nm). Then re-install the headlamp bracket, install the front fender, install the front wheel and the brake caliper When the motorcycle is again ready for the road adjust the headlamp and road test the motorcycle.






Feb 10, 2011 | Harley Davidson FXD Dyna Super Glide...

1 Answer

How do you remove the forks on a 2001 fxd superglide






Hopefully you will glean all you need to know from this but if you want or need more information or more FXD specific information PLEASE H

Hopefully the information below will be okay BUT if you need any more or any more specific information please post a comment and describe what you want/need.

REPLACING FORK OIL Replace front fork oil at every 20,000 mile (32,000 km) service interval and/or prior to storage.


ALL BUT FXDX & FXDXT models


Raise and support the motorcycle so the front end is off the floor and the forks are fully extended, on FXDL models, remove the center plug from each fork cap, on all other models, remove the fork tube caps, remove the drain screws from the bottom of each fork and drain the fork oil, replace the drain screws and washers and tighten the screws

to 13-17 in-lbs (1.5-2.0 Nm) THEN see Table 1-6. and fill the fork with Harley-Davidson TYPE E FORK OIL (Part No. HD-99884-80) as set out in the Table. THEN if apart assemble the forks as follows:


a. FXD, FXDXT, FXDWG models: install both fork tube caps and tighten them to 11-22 ft-lbs (14.9-29.8 Nm).

b. FXDL models: install center plugs and tighten until secure.


Fork oil amounts can be measured two ways: use the oz./cc measurement if fork is left in frame; use the in./mm measurement if the fork is disassembled in which case the oil level is measured from the top of the fork tube with the spring removed and the fork fully compressed.


Table 1-6. Type E Fork Oil Amounts for 2001 DYNA


MODEL OZ CC IN. MM

FXDXT 11.5 341 6.10 154.9

FXDWG 12.0 356 7.28 182.9

FXD 10.6 314 6.69 169.9


PART NO. SPECIALTY TOOL

HD-41177 Fork tube holder

HD-41549A Fork spring compression tool

HD-41551 Spring plate tool

HD-36583 Fork seal installer

HD-59000A Pro-level oil gauge



FRONT FORKS: FXDX & FXDXT 2.20

REMOVAL

Raise and support the motorcycle so the front end is off the floor and the forks are fully extended, remove both front brake calipers and the front wheel, remove the front fender, remove the front fairing, remove the headlamp bracket and attach the headlamp to the frame using a rubber bungee strap, loosen the upper and lower triple clamp pinch bolts and pull the fork sides from the brackets.


DISASSEMBLY

Remove the stopper ring, remove the spring preload adjuster but DO NOT unthread the rebound adjuster from the damper rod because incorrect assembly could result in reduced adjustment range. THEN unthread the fork cap from the fork tube and allow the fork leg to drop, exposing the spring, THEN get a FORK SPRING COMPRESSION TOOL (Part No. HD-41549A) on the spring collar, turn the screws in to engage the holes in collar, compress the spring until the SPRING PLATE TOOL (Part No. HD-

41551) can be positioned between the spacer and the spring collar, THEN hold the fork bolt and compression adjuster, remove the fork bolt from the compression adjuster, remove the spring adjuster plate from the fork bolt, remove spacer, spring collar and spring, pour out the fork oil by pumping the fork leg and rod 8-10 times or until rod the moves freely. THEN position fork slider in vise using a FORK TUBE HOLDER such as (Part No. HD-41177) to avoid damage. THEN remove the socket head bolt, remove the damper from the fork tube, remove the cover from the slider, remove seal and stopper ring, pull the fork tube out of the slider, remove the oil seal, spacer and guide bushing from the fork tube.


CLEANING AND INSPECTION

Measure the fork spring free length and replace the spring if it is shorter than 17.00 in. (431.8 mm), check the fork tube and the slider for score marks, scratches or abnormal wear, check the slide and guide bushings for excessive wear or scratches, set the fork tube on V-blocks and measure runout which should not exceed 0.008 in. (0.2 mm).


ASSEMBLY

Coat the oil seal with TYPE E FORK OIL, before installing the slide bushing and guide bushing, lubricate them with fork oil, THEN install the guide bushing and the spacer seal noting that the guide bushing opening must be oriented to the side and NOT to the front or rear, THEN slip the slider into the fork tube, place the slide bushing over the fork tube until it rests on the slider, drive the guide bushing with the spacer seal into the slider, lubricate a new oil seal with TYPE E FORK Oil, drive the oil seal into the slider using FORK SEAL INSTALLER (Part No. HD-36583). install the stopper ring and dust seal, (if the rebound adjuster was removed from the damper rod bottom the lock nut on the threaded portion of damper rod, holding a thumb on the detent spring and ball, back out (turn counterclockwise) the rebound adjuster to the last "click." and then turn down (clockwise) 17 "clicks", thread the rebound adjuster onto the damper rod until the adjuster stops at maximum thread engagement (but do not force it), thread the locknut onto the damper rod up until it contacts the base of the rebound adjuster and tighten it in place), THEN holding the slider in a vise while being careful not to damage it. install the damper tube into the fork tube and tighten the socket screw and washer to 22-29 ft-lbs (29.8-39.3 Nm). THEN pour half the TYPE E FORK OIL into the fork tube, slowly pump the damper rod 10 or more times, position the damper rod in the fully bottomed position and pour the remaining amount of TYPE E FORK OIL into the fork tube. THEN using a PRO-LEVEL OIL GAUGE (Part No. HD-59000A) or similar adjust the oil level to 5.04 in. (128 mm). THEN carefully clean and install the spring, the spring collar, and the spacers with the sharp edge created when they were stamped out when manufactured, facing the collar. THEN using a FORK SPRING COMPRESSION TOOL such as (Part No. HD-41549A) push spring collar down and place a SPRING PLATE such as (Part No. HD-41551) between the spacer and the spring collar, install the fork cap and tighten it against the rebound adjuster to 22-29 ft-lbs (29.8-39.3 Nm). THEN tighten the fork cap onto the fork tube to 11-22 ft-lbs (14.9-29.8 Nm), install the spring adjuster plate, replace the O-rings on the spring preload adjuster and lubricate them with fork oil. THEN install the spring preload adjuster and the stopper ring and carefully drive the slider cover into the slider.


INSTALLATION

Insert both fork side assemblies up through the fork stem and bracket and upper bracket and tighten the fork stem bracket pinch bolt(s) to 30-35 ft-lbs (40.7-47.5 Nm). Then re-install the headlamp bracket, install the front fender, install the front wheel and the brake caliper When the motorcycle is again ready for the road adjust the headlamp and road test the motorcycle.

Oct 01, 2010 | 2001 Harley Davidson FXD Dyna Super Glide

1 Answer

530 exc spacing between front fork & spacer


front axle installation: looking at the front of the bike:

slide the wheel into position and insert the axle from the left. with axle now through the right hand fork, install nut and tighten the left fork pinch bolts to secure the axle for tightening the nut. tighten the nut to 29.5 ftlbs. and loosen the left pinch bolts. now tighten the right pinch bolts and compress the front suspension while the left (from front) is still loose. now allow suspension to rest naturally and tighten all 4 pinch bolts to 11 ftlbs.
your done.......the axle is tighten against the rotor side and the other fork is then tighten in it's natural position so as not to cause premature seal and bushing failure and increasing stiction.

Sep 27, 2009 | 2008 KTM 530 EXC-R

1 Answer

Top front forks tightening


dont stress,,,,,,, torque em to 65 lbs

Sep 23, 2009 | 2004 Harley Davidson XL 883 Sportster

1 Answer

I need the torque settings for changing the wheels on my BMW HP2 as I have lost the settings for the front axle,front brake caliper and rear wheel bolts


BMW workshop DVD says Front axle M22x1,5 (greased) = 50NM Front axle pinch bolts = 8NM Brake caliper to fork bolts = 30NM Rear wheel bolts M10x53x1,25 = 60NM
Brake caliper to fork torque needed if changing to SM wheels. Method. Torque greased axle bolt to 50NM, then compress forks several times without using brakes, then tighten both LHS axle pinch bolts to 8NM, then tighten both RHS axle pinch bolts to 8NM. Then test your brakes are working. Front finished. Rear. Torque to 60NM. I torque every second bolt as I work my way around the 5 Torx screws until they have all been torqued and double checked

Jul 22, 2009 | 2006 BMW HP2 Enduro

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