progressive suspension install sound - 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 04-11-2014, 01:37 AM Thread Starter
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Join Date: Jun 2010
Location: Rolla, Mo
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progressive suspension install sound

Hi everyone,

The latest example of my Hypochondriac motorcycle maintenance is with my front forks. Left one started leaking a few weeks ago, so time to bite the bullet and do a rebuild whilest installing my progressive springs I bought a year ago.

I did do a rebuild....not the air compressor method (I have the dampener bold remover and my 80 psi air compressor didn't want to blow the seals). While I was putting everything back together the tubes were sliding up and down nice and smooth and I heard no strange noise.

Then I put the forks back on the bike and it makes kind of a weird metallic squeeky noise when I compess them. The bike did not make such a noise before.

Is this noise normal (that is the springs make this noise) or did I screw something up along the way?

FWIW: I haven't had a chance to ride her because it is 1:30am and I want to go to sleep.

-Stefer

PS -- lesson learned. Kawasaki parts for dampener removal do NOT work. Waste of 50 bucks. I ended up ramming the tool into the rear axle bolt (24 mm) and replacing it afterward (only 24mm bolt I had at the time). You are better of going out and buying a bunch of wratchet extenders and a 24 mm bolt and socket.

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

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post #2 of 7 Old 04-11-2014, 04:12 PM
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How many miles did you have when the fork began leaking?
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post #3 of 7 Old 04-11-2014, 04:21 PM Thread Starter
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Just over 10k. I suspect my happy trips fork brace does not seal correctly with the fork boots. Some RTV sealant will take care of that in the future.

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

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post #4 of 7 Old 05-10-2014, 10:47 PM
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You didn't happen to put your Progressive springs in with the tight coils up did you? Progressive told me that they can go in either way, but are quieter if you put the tighter coils down.

I just installed some in my '05 and I haven't experienced any unusual noise.
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post #5 of 7 Old 05-10-2014, 10:57 PM Thread Starter
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I don't remember at this point. I'm 99% sure I put them in the same orientation as each other, whatever that may be. At this point I'm not concerned. It is not audible with the engine running.

As of today I've got ~200 miles on em including a 2 hour ride today. Big fan right here.

Now just need a front brake upgrade and stopping will be pleasant.

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

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post #6 of 7 Old 05-11-2014, 09:18 AM
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Glad you are happy with the change. Good to know for future.
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post #7 of 7 Old 05-11-2014, 03:31 PM Thread Starter
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Posts: 576
Quote:
Originally Posted by bl4935 View Post
Glad you are happy with the change. Good to know for future.
Others have reported significant improvements from more preload by using PVC spacers that are longer than the stock spacers. In hindsight I would have tried that first given the cheapness.

But the springs are in there now and I'm happy.

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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