Gen 1 fork bushings- Made of gold?! - 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 5 Old 04-28-2020, 08:33 AM Thread Starter
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Gen 1 fork bushings- Made of gold?!

Hey guys, long time since I logged in here!

I have a pair of Gen 1 fork in need of bushings. I went shopping and got sticker price! $120+ for bushings?! And you can grab Gen 2 bushings for like $30. I've never seen bushings this expensive. What's up?

Are there any other bushings that will interchange? By the time you do the seals your are well over $150. I would swap on different/better forks before I spent that much.

Thanks for any advice.
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post #2 of 5 Old 04-28-2020, 10:13 AM
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you can get them cheaper than that;

I know there are some aftermarket bushing kits for the Gen2, I've never checked on the Gen1 as I prefer to do this particular job once so I stick with the OEM ones. .....Actually I think I have a spare set somewhere...

Here's a related post showing some of my thoughts on a fork swap;

Several things, the biggest is a new front wheel/hub and brake system. As I told you in that other thread, there is no free ride and the USD fork conversion has it's own set of issues to deal with.... Not saying there isn't an allure to it just that there are good reasons more folks don't do it. When I did the math prior to making the decision to stick with the stock forks and go with Cogent's DDC's, my total came to $2,000 - $2,500 for the USD fork conversion vs. about $350.00 and less than an hour for the Cogent stuff.

After the additional expense, fork rebuilding, respringing, revalving, dealing with the rear suspension travel issue, gauge cluster, speedo, turning radius still have a smaller hub with a smaller axle, smaller bearings and when compared to the SV caliper 320mm rotor mod, a much smaller brake caliper, pad and rotor......all of which are fine for MX use and less fine for dual sport use.

There is no doubt as to the superiority of the modern MX fork.....but unless you have it resprung and revalved properly, it isn't going to work as good as a set of DDC's and springs in the stock forks.......and even if you do those things, the rest of the KLR isn't up to making full use of them anyhow.

I'm just making you aware of all the issues; if you still want to do it after all that, knock yourself out.
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post #3 of 5 Old 04-28-2020, 10:46 AM
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Location: Lander, Wyoming
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Try an All-Balls or Pivot Works fork rebuild kit from your favorite supplier.
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post #4 of 5 Old 05-04-2020, 01:10 AM Thread Starter
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Join Date: Aug 2016
Posts: 529
Thanks guys. Unfortunately I just don't see any affordable bushing kits for a Gen1. RMATVMC has the best price I see,and it's still over 80 bucks all said and done.

Not looking to do another fork swap. I swapped XR650R forks on to my KLR for under $200 bucks. I reused those stock Gen1 forks on my XL500
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post #5 of 5 Old 05-04-2020, 01:47 PM
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