Renewing the fork seals on #3 KLR - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 17 Old 04-25-2010, 01:19 AM Thread Starter
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Join Date: Oct 2006
Location: Good Liver, Oregon
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Arrow Renewing the fork seals on #3 KLR

I had to replace both fork seals on this bike today
http://adventuresidecar.com/?p=355

I removed the fairing


I loosened the fork caps


and removed the brake


next I removed the axle and front wheel




removed one fork leg


cleaned off the spooge


& popped the clip out

Vernon
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Last edited by Tom Schmitz; 02-12-2015 at 12:13 PM.
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post #2 of 17 Old 04-25-2010, 01:21 AM Thread Starter
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...I dropped the spring and spacer out and drained the oil


I replaced the cap and pumped in 70# of air. The seals didn't budge so I took a break. Eventually it popped out.


I removed the bushing and washer, pumped out the the remaining oil.


wiping the fork tube clean I re-installed the bushing & washer and tapped home the new seal and scraper using some 1 1/2" pvc for a driver.


I made a dipstick to measure the oil putting in just under 440 mL of BelRay 10w to bring the level to 18mm.




http://adventuresidecar.com/?p=367

Vernon
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post #3 of 17 Old 04-25-2010, 01:22 AM Thread Starter
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http://adventuresidecar.com/?page_id=72

I replaced the spring and washer and made a 1" over(6 1/2") preload spacer from 3/4" schedule 40 pvc.






I installed the left leg in the triple tree and removed the right fork, repeating the process.
I torqued the pinch bolts to 18# working each pair, back and forth until the torque wrench clicked as soon as pressure was applied.


The rest was just buttoning things up: new brake pads replaced the oil fouled pads, mounting the front wheel and the fairing, tightening the fork caps down.

Vernon
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Last edited by Adventure Sidecar; 04-25-2010 at 01:36 AM.
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post #4 of 17 Old 04-25-2010, 12:19 PM
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Great job and write up. Sidecar looks great. Puppy looks very interested in learning the process.

94 KLR,tank guards,sw motech centerstand,Doo done, african switch,mirror dampners, powerpegz, twisted throttle fuses, aluminum skidplate, Bigcee shark disc and jug holder and subframe upgrade, progrip grips,maier handguards/brushguards, avon distanzias,fmf q4 exhaust, headlight guard, handlebar risers, billet rear brake reservoir bracket and guard, dual star shifter,garmin 2820 gps, tmod,disc cover, pcv mod,corbin flat
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post #5 of 17 Old 04-25-2010, 09:46 PM
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I have to ask.. What bike is that on the right with a dirt bike tire on it?

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post #6 of 17 Old 04-26-2010, 12:03 AM Thread Starter
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Quote:
Originally Posted by Paper View Post
I have to ask.. What bike is that on the right with a dirt bike tire on it?

Suzuki Bandit 600





Vernon
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post #7 of 17 Old 04-26-2010, 07:21 AM
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Very cool!! I had to ask!!

I'm thinking you guys have a pretty good time on the weekends??
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post #8 of 17 Old 04-26-2010, 07:41 AM
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hey , can you tell me what tire are fitted on that bandit 600 and also the size . Planning on building a scrambler but i'm having dificultis finding the right tire

Cheer's
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post #9 of 17 Old 04-26-2010, 08:03 AM Thread Starter
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Quote:
Originally Posted by Marco F. View Post
hey , can you tell me what tire are fitted on that bandit 600 and also the size . Planning on building a scrambler but i'm having dificultis finding the right tire

Cheer's
The rear is the same as I run on my KLRs:Kenda K270 5.10 x 17"

Not sure the exact size on the front, but it's a Cheng Shen Trials

Vernon
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post #10 of 17 Old 01-04-2015, 01:49 PM
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Not sure how I didn't see this thread until now. I had leaking seals so I tried this technique. It didn't work because I forgot to remove the clips...doe.


Word to the wise, if you choose to rebuild like I did: I ended up paying $50 for the custom tools to remove the bolt way down there and rebuilt the whole thing. Word to the wise -- the custom tools do NOT work. I ended up jamming the tool into the rear axle nut and when I did that, it worked perfectly. Obviously this screwed the nut up, but I bought a new one for the axle. Rather than buying the $50 of tools, get a bunch of wratchet extenders (probably 2-3 feet of em, then figure a way to utilize a nut equal to the rear axle nut to break it.

2006 Red KLR 650

Modifications:
1)Doohickey Planned and purchased 2)Aftermarket Grips 3)Grip Heaters 4)Happy Trails Hard Luggage Rack 5)20 mm ammo cases planned soon 6)Aftermarket Exhaust 7)Thermobob 8)Happy Trails Fork Brace 9)Stainless Steel Oil Filter 10)Magnetic Drain Plug

See profile visitors post for details and planned mods.
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