Fork seals - 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 7 Old 03-17-2007, 07:56 PM Thread Starter
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Join Date: Oct 2006
Location: Klamath Falls, OR
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Fork seals

Ok,
I need some info, I cannot find my manual, I probably left it is someone garage.
I am replacing my fork seals and need the proper steps to get the forks apart.
Also need the torque specs for the triple trees.
Other than that it has been a productive day.
Changed the oil
Replaced front break line with a different braided steel line
Replaced break fluid
Installed a third break light
Cleaned the K & N air filter
Info would be great so I can break her down then get her back together.
Thanks

Craig
KLR 650 - A18
Triumph Sprint ST - 2008
Polaris Sports Man 300 4x4 - Wife's
Polaris Sports Man 400 HO 4x4
28 foot Travel Trailer
Not enough time to play
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post #2 of 7 Old 03-17-2007, 08:15 PM
 
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I have both manuals here.... are you still there?

I show on page 11-2 from the Service manual that the tree has 15 foot lbs on each fork. Outer brackets only.

So far?

Last edited by X6_Hustler; 03-17-2007 at 08:22 PM.
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post #3 of 7 Old 03-17-2007, 08:23 PM Thread Starter
2nd Gear
 
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Yes eating dinner while surffing.

Craig
KLR 650 - A18
Triumph Sprint ST - 2008
Polaris Sports Man 300 4x4 - Wife's
Polaris Sports Man 400 HO 4x4
28 foot Travel Trailer
Not enough time to play
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post #4 of 7 Old 03-17-2007, 08:29 PM
 
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How can I help you with the fork assembly procedure?
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post #5 of 7 Old 03-17-2007, 08:35 PM Thread Starter
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I need to know how to get them apart.

Craig
KLR 650 - A18
Triumph Sprint ST - 2008
Polaris Sports Man 300 4x4 - Wife's
Polaris Sports Man 400 HO 4x4
28 foot Travel Trailer
Not enough time to play
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post #6 of 7 Old 03-17-2007, 08:44 PM
 
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Posts: 284
Front Fork Disassembly

1. Before removing the front fork from the frame, release the air and loosen the top bolts.

2. Remove the following parts:
Caliper, brake hose
Front wheel
Rubber boot
Fork Tube
Top bolt, spring guides, main spring
Drain screw, pump out the oil into a container

3. Push the inner tube all the way in, and remove the Allen bolt on the bottom of the outer tube using the cylinder holder handle and adapter (special tools)

4. Remove the circlip and dust seal with a sharp hook.

5. Holding the inner tube by hand and keeping the fork leg in a vertical position, tap the outer tube on the upper end with the driver (special tool) until the outer tube falls off the inner tube. Face the big end of the driver downward.

End of disassembly....

Of course you have no benefits of the drawings I have..... does this help?
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post #7 of 7 Old 03-17-2007, 08:48 PM Thread Starter
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Posts: 440
That is what I was looking for. I thought thats how it came apart but wanted to double check.

Thanks

Craig
KLR 650 - A18
Triumph Sprint ST - 2008
Polaris Sports Man 300 4x4 - Wife's
Polaris Sports Man 400 HO 4x4
28 foot Travel Trailer
Not enough time to play
MotoPhoto is offline  
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