Join Date: Mar 2015
Location: Colorado mountains
I realize that I'd have to disassemble the forks to measure, drill and flush, but that'd be a one time thing. I don't think there'd be much risk of stressing the tube; I'm only talking about a 6mm hole, max, and possibly only 4mm. IIRC, the drain plugs in my old Hondas were only 4mm Phillips head screws.
As far as flushing the old oil, and getting the air out, I've always just pumped the forks til they stop draining, and gently pump them again after refill, though that's not really necessary if you just use a measured amount of oil.
pdwestman, yes, the plan is to have the hole right at the bottom of the bore, and on the rear side of the slider. If I do this (a good snowy day project), I'll relay the measurement; not sure if they changed the forks that much from the Gen 1s or not.
Thanks for everyone's input and ideas; it's just a thought at this point, but I do love to tinker :-).
'08 KLR 650