Ricor Intiminator Fork Valve installation - UPDATED - 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 1 Old 09-11-2009, 03:20 AM Thread Starter
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Join Date: Sep 2006
Location: Sacramento, CA
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Ricor Intiminator Fork Valve installation - UPDATED

UPDATED 9/13/2009

Needed to go to the USPS so I took the KLR. As soon as I got on the Freeway I knew the Ricor Intiminator Fork Valves were something special. Smooth, tracks straight, did I say smooth. Left the USPS and headed to the River Road that runs through the Delta and agriculture land (agland). I did not avoid the older rougher portions of the River Road and was very impressed. The forks just sucked up all the roughness, tracked straight, handled the worst in the corners, my hands did not know what to do but hang-on and enjoy the ride. There is a short five mile road that I had never ridden before so off I went. There is a twisty road that leads to the short five mile road. I rode it faster than I had ever ridden it and know I can go faster. The forks do not vary in the corners whether the road is rough or smooth. Turning on to the five mile road I found a typical aged agland surface levee road then...I see a gravel covered washboard road. At first I had reservations though after a few moments my confidence level was as good as the KLR felt, very good. The KLR slipped at times though I realized it was the rear wheel (shock) slipping. The front forks handled the washboard and gravel piles with ease. I am loving the Ricor Intiminator Fork Valves. Coming off the gravel to the asphalt was a straight edge of raised asphalt, I did not feel a large impact or any traction disturbance, except the rear wheel. I crossed over the Sacramento River at Walnut Grove and headed to some very rough agland roads. I am totally surprised that my hands or the KLR were not moving all over the road as usual. I was riding 85 mph where I normally would ride 55-60 mph, V-Strom or KLR. This road has large asphalt cracks and separations and all I did was watch them roll under the KLR. Railroad tracks not a problem. Eventually on to the freeway again where three miles have had the asphalt stripped off for a future resurface. I have recently ridden the same surface without the Ricor Intiminator Fork Valve upgrade and the KLR got moved around the lane. With the Ricor Intiminator Fork Valves the KLR held its line and I could ride where I wanted to. This writeup is no bull though there is a down side. If the Ricor Intiminator Fork Valves are this good (great) how good is the Ricor rear shock! and that cost some serious cash. I do know my V-Strom DL1000 will have the Ricor Intiminator Fork Valves installed before I leave for a two week Las Vegas / SoCal trip.

Riding on Ricor Intiminator Fork Valves is almost like cheating.

ps - I forgot to mention the lack of dive during heavy braking. The reasoning for not mentioning it was I did not experience any.

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After having Ricor Intiminator Fork Valves and Amsoil Synthetic 5W and a knee injury for many months I finally got around to completing the installation yesterday.

If I was not taking photos (to come later), making notes, excessively flushing the the forks, and excessively draining the forks, this project could have been completed in less than two hours. The Ricor Intiminator Fork Valves install easily.

-Raise the KLR using a motorcycle jack or centerstand. The front wheel needs enough room to remove the fork tubes without hitting the floor.
-Remove the front brake caliper, upper brake line mount, speedo cable, reflectors, and front wheel.
-Remove the Eagle fork brace if you have one.
-Remove the fork tube caps and spacers or MotoWizard Preload Adjusters if you have them.
-Remove the fork oil drain screws at the bottom of the forks. Beware of how far the old fork oil initially shoots out (18" maybe) the sides of the forks. Drain the forks enough to reinstall the drain screws.
-Remove the fork springs washers and springs.
-Loosen the fork tube clamp bolts (8).
-Slide the fork tubes out of the triple clamp, turn them upsidedown and drain the remaining old fork oil. Make sure the fork tubes are compressed.
*I flushed (three times) the fork tubes with some ATF I had on the shelf. Flush and drain the tubes until you feel good about getting the old gray matter out.
-The instructions say to pour some of the new fork oil in the tubes and bleed them by cycling the fork tubes before installing them. I waited until the tubes were installed before adding fork oil. Either way is good though Ricor is more correct.
-Bleed the forks by slowly pumping the tubes, completely closed to completely extended.
-Set the height of the fork tubes.
-Insert the axel to align the fork tubes.
-Tighten the lower triple clamps and leave the upper triple clamps loose (they should be loose when the stock fork tube caps or MotoWizard Preload Adjusters are installed).
-Insert the Ricor Intiminator Valve and push to the bottom using the fork spring then remove the fork spring.
-Reinstall the components except the fork spring washers and fork springs, and the fork tube caps and spacers or MotoWizard Preload Adjusters.
-Compress the fork tubes, fill with Amsoil Synthetic 5W, and set the fluid level.
*I use a manual siphon that I built. This siphon uses a 3 ounce syringe and a tube with a .125" ID. This works well with ATF and other non-synthetic fork oils. I found that the Amsoil Synthetic 5W would drain back into the fork tube when there was a sunstantial amount of fluid in the syringe. I kept siphoning until the levels were the same. In the future I will uses a siphon tube with a .062" ID.
-Extend the fork tubes and install the fork springs and washers.
-Install the stock fork tube caps and spacers or MotoWizard Preload Adjusters. Be concerned about not cross-threading.
-Tighten the upper triple clamps.
-Double check that everything is installed and torqued correctly.
*The speedo cable could have slipped out of the speedometer. Slide the cable into the speedo adapter, raise the fastener to where you can see the cable, rotate the front wheel until you see the cable rotating, start the fastener, spin the front wheel and check the speedometer to see if it is functioning. If so, thighten the fastener.
-Time to lower your KLR and prepare for a test ride.
-This is not a time to get overly excited since you will be riding a new front suspension. Test the suspension for compression or dive. Do this at lower speeds and work your way to your normal riding speeds.

**The streets where I live have reasonably high and wide speed bumps with many being doubles. I was able to ride through them at 30 MPH with the restriction being the rear shock. I could ride over them at 40 MPH though the rear shock really bucked me when I was sitting and would become airborn when I stood. The forks were VERY SMOOTH at both these speeds and probably would handle 50-60 MPH. I knew the Ricor Intiminator Fork Valve upgrade was going to be good though I was very impressed how they smoothed the frontend of the KLR. This Ricor Intiminator Fork Valve upgrade is well worth the time and expense.

My KLR Forks:
-Ricor Intiminator Fork Valves / Amsoil Synthetic 5W.
-Progressive Fork Springs / no spacers.
-MotoWizard Preload Adjusters / extended 16mm of 24mm(maximum).
-Top of the fork tubes are flush with the triple clamp.

Previously used:
-ATF fluid
-Progressive Fork springs / no spacers.
-MotoWizard Preload Adjusters / extended 12mm of 24mm (maximum)
-Top of the fork tubes are flush with the triple clamp.

***I was not dissatisfied with the previous setup. It handled well over bumps, rough roads, and very smooth on highways. I am surprised at the increased smoothness of the front suspension and not surprised with the Ricor Company. Ricor always provides excellent products and support and the Ricor Intiminator Fork Valve is an excellent upgrade.

On the 19th we are leaving for a four day (six day for me) trip to Crater Lake and back. I will report more after this trip and let you know how well the frontend handles Smoothies and Twisties. Sorry there is no dirt or gravel planned for this trip.

Tim

2005 KLR 685
2015 Yamaha Super Tenere ES, 5/23/2015
2012 Yamaha Super Tenere; Purchased 7/30/2011; Sold 5/23/2015

Last edited by tomatocity; 09-14-2009 at 12:45 AM.
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