07 Front Forks Loose - 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 12-14-2007, 12:05 PM Thread Starter
Join Date: Dec 2007
Posts: 3
Unhappy 07 Front Forks Loose

Hello all,
This is my first post although I have been lurking for some time. Just had a quick question. My bike started at about 500 miles with a loose feeling in the front forks when I would hit washboards on a gravel road. I checked everything out and it seemed fine. At 1000 miles I noticed that the main fork nut was loose and I tightened it up only to feel the loose forks again.
Do you think my bushings are shot for riding that 500 miles with the nut loose?
Is there an adjustment somewhere else to tighten it up?

thanks for your help
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post #2 of 7 Old 12-14-2007, 06:42 PM
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Join Date: Sep 2006
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Nothing should be worn out. Loosen up the top nut, loosen the 4 upper triple tree bolts, look under the tree and you'll see a nut with notches in it..use a screwdriver and tighten that nut...use the screwdriver like a punch...go maybe an 1/8 of a turn...rotate the bars back and forth a few times, if it feels notchy you need to loosen the spanner nut a touch..when you have that done tighten the big nut on top, then the 4 tree bolts..go easy..only about 12 foot pound on those.

I think www.bigcee.com has some info on this for you too.
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post #3 of 7 Old 12-14-2007, 08:29 PM
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Location: London, Ohio
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Yeah, I'd be surprised if bushing went bad that fast. I assume you've checked the front wheel bearings? Short of that you may wanna invest in a fork brace. Stupid things do make a big diffrence.

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post #4 of 7 Old 12-15-2007, 01:46 AM
Join Date: Jun 2007
Posts: 25
this is the best info i have on your problem, you have to sign up to view it and its a valuable place for other klr information too, its free. http://klrworld.com/forums/index.php?topic=1391.0
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post #5 of 7 Old 12-16-2007, 09:46 PM Thread Starter
Join Date: Dec 2007
Posts: 3
Thanks for all the information fellas. The website you directed me to Larryboy had both of my problems listed on the known problems part. I will bypass the clutch safety switch to fix the starting in only neutral problem, and I should be able to adjust the slack in forks.
Thanks again
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post #6 of 7 Old 12-19-2007, 02:04 PM Thread Starter
Join Date: Dec 2007
Posts: 3
Angry Update

Just an update for you guys,
I tried adjusting the steering on my bike only to find the same wiggle on the washboards. I broke down and took it to the dealership where they found that the bearings in the steering were shot. They ordered new bearings and told me that it would be covered under warranty. It is still going to cost me $160 just to have the first service done, and they are not even changing my oil! Anyone else heard of this problem?
How much did you guys pay for the first service on your bikes?
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post #7 of 7 Old 12-19-2007, 02:08 PM
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Join Date: May 2007
Location: Richmond, Ky
Posts: 1,980
I did my own first service and ever service after that. I also checked my valves as the dealer does not even do that in the first service or second without charging for it. I am not paying someone over a $100 to change my oil and finger test to see if any bolts are loose. As long as you document your service with reciepts and date and mileage, they still have to honor your warranty. Just buy your oil and filter there and keep a binder with the reciepts. I have not heard of new steering bearings bad right off the bat, but it is mechanical and anything can slip by quality control. At least it is covered. Good luck with everything.

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