[badlandstom]

I got sick of paying suspension shops big bucks for an easy job. About 5 years ago, I finally decided to teach myself how to rebuild and revalve forks. Now I need to learn shock maintenance...

Im in the same boat. Paid big bucks for having new progessive springs put in by the dealer. seals started leaking the next season, Decided to learn to do seals myself. Turns out the dealer did a terrible job! Spacers weren't equal length and both were way too long, This web site, and some of the available videos are a great source of assistance, Im having a blast learning how to wrench on my own KLR's and it gives me confidence that its getting done right! The catalyst for doing my own work was when the dealership in Sioux Falls quoted me $1500 bucks to install a doohicky! No joke!

 

[Biggs3118]

it gives me confidence that its getting done right!

Peace of mind is a 'beautiful' thing.

The catalyst for doing my own work was when the dealership in Sioux Falls quoted me $1500 bucks to install a doohicky! No joke

Most dealerships have gone to 'hell in a hand basket' or put differently are 'smoking something'. I've spent a lot of years working in the MC industry and it's definitely not what it used to be, which is sad to see. Quality keeps being given a back seat in favor of 'profits'.

 

[KLR-Mule]

The catalyst for doing my own work was when the dealership in Sioux Falls quoted me $1500 bucks to install a doohicky! No joke!

Correction: stealership.
This doesn’t surprise me. They can charge whatever they want if someone is dumb enough to pay for it.

I would charge you a free 30mins of my time & a tall can . It’s a fast & easy job.
Glad you opted to NOT pay that stealership for their doohickey replacement.

 

[badlandstom]

The upside of doing my own "doo" was when I ran into a problem I called the "800" number for Eagle Mike. He called me back within a half hour and after discussing my situation we'd arrived at the solution. that kind of service is unheard of in this day and age. I've asked his advice a few more times since then. I also have to give kudos to some of the regular contributors on this site. Couldnt have done the things I have done without their help. Im retired and wrenching turned out to be a whole new pastime. I've done three "doos", a couple of fork seal replacements and just completed a clutch re-build two weeks ago. First time efforts aren't the quickest, I destroyed a couple gaskets here and there, but I've got patience and dont quit until things are right. Like the song goes, "I get by with a little help from my friends."

 

[PeteK]

Glad to hear you have acquired a new hobby, "Zen and the Art of Motorcycle Maintenance." If you've never read that book, you'll have a deeper appreciation for it now. Welcome to the brotherhood of "grease-under-your-fingernails."

Just curious, why have you done three 'doos? Helping other people out, or you just had to do it three times to get it right?

 

[badlandstom]

Mcuh to my parents dissapointment I did read Zen and the Art of Motocycling when I was kid back in '68 or '69. Getting a copy of the maintenance "Zem" would be a real hoot after all these years. thanks!
As far as multiple "doo's" go,,,,,, I've mentioned in previous posts I did a lot of guiding. For me, guiding was also about teaching. Over fifty years of doing that has resulted in quite a few "friends"- multi generational now- who all share a love of the outdoors. At sixty, old injuries required.Orthopedic surgeries for the second and third time.and some parts just couldnt be fixed anymore. Dual sport bikes were a way for me to still do what I love, which is getting out in the wild places and camp. Seems like a lot of folks in my little outdoor community thought it looked like fun. I look for good deals on used bikes, make recommendations and now end up "teaching" off road riding skills and how to camp off a bike. Two of the bikes we found were KLR's that hadn't had the "doo" done yet, so I volunteered for the job. It actually started with tires, of all things. I've been riding since '66 and never once had a flat tire that needed road side repairs. After seeing so much attention being given to trail side tire repairs when dual sporting, I decided that was a skill I needed. The first season I think I changed out sixteen sets of tires on both my bikes and for a few friends. I'm still no expert but I've gotten pretty handy at changing out tubes, patching, and tires when the need arises. My experience is that a lot of folks buy what they're told they need (spare tubes, irons, compressor etc.) but dont have a clue how to actually use that stuff. As far as I know, you cant buy "skill" off the shelf at Walmart. Sorry for such a long answer. I'm just one of those guys who believes in "passing it on". Happy to report that its been funny to see "first" bikes might not be KLR's, but most often the next one is Here's to reliability and simplicity!

 

[banditcilik]

What will be the safest and most effective way to clean up the internal without separating the fork tubes? Can I spray degreaser into the tube or just pour some ATF and drain?

 

[KLR-Mule]

What will be the safest and most effective way to clean up the internal without separating the fork tubes? Can I spray degreaser into the tube or just pour some ATF and drain?

ATF will work just fine. Pour a half-quart in each tube, cycle each fork tube a few times, & dump out. Continue to cycle each fork while draining. This will ensure that all the flushed ATF is removed.
I would not use degreaser.

After they’ve been flushed, you can also use ATF as an alternative to 10wt fork oil.
KLR’s aren’t picky…

 

[RHodgins]

I don't have the long T tool to hold the nut inside the tube

I made a "special" tool. Ground down socket welded to some threaded rod I think. Pretty basic.

 

[RHodgins]

Once you've had the forks apart and seen what comes out you'll want to separate them and do a good cleaning each time.

 

[banditcilik]

ATF will work just fine. Pour a half-quart in each tube, cycle each fork tube a few times, & dump out. Continue to cycle each fork while draining. This will ensure that all the flushed ATF is removed.
I would not use degreaser.

After they’ve been flushed, you can also use ATF as an alternative to 10wt fork oil.
KLR’s aren’t picky…

Thanks

Once you've had the forks apart and seen what comes out you'll want to separate them and do a good cleaning each time.

I don't plan to separate the tubes. I have a feeling I will mess things up.

 

[StarfuryTH]

Thanks

I don't plan to separate the tubes. I have a feeling I will mess things up.

You won't. There's not much there to mess up.

The only things even marginally sensitive in there are the bushings, and as long as you don't scratch the friction surfaces on them, they'll be fine.

 

[RHodgins]

Thanks


I don't plan to separate the tubes. I have a feeling I will mess things up.

They are dead simple. Do one at a time so you have a "guide" if need be. Each time you tackle a task like this it can seem daunting, but once you're done it's like "wow that wasn't too bad at all".

 

[banditcilik]

Can anyone confirm the seal spring side should face the oil (down) or the outside (up)?
I checked some videos where the dude says facing outside (up). The old seal that I removed faced down and it doesn't make any sense to face the spring up since that side doesn't have much surface to receive impact when seating it.

 

[StarfuryTH]

Spring side definitely faces down, towards the oil.

 

[BkKcaliKLR]

I just had a place in Salinas CA do a bunch of work to my bike.. $120 an hour! He is honest and gives an up front quote on hours.

 

[BkKcaliKLR]

I just had a place in Salinas CA do a bunch of work to my bike.. $120 an hour! He is honest and gives an up front quote on hours.

My boss charges me out as a lead carpenter at 75 an hour and can’t believe the hourly rate:/

 

[banditcilik]

Spring side definitely faces down, towards the oil.

Thank you. Actually the seal that was on it has 2 spring lips on both sides but anyway I put the new seal with spring face down. I can't believe the old fluid looks like squid ink.
I was planning to just pop the old seal by air pressure and replace without further disassembly but the left fork didn't budge. So to make my own tool I used a 5/8 threaded rod and pair of 5/8 nuts to hold the rod and 5/8 lock nut for the tip that goes to the damper. The nut is tad smaller than 24 mm most folks use but it worked perfectly. I used the plastic bag to slide the seals in but unfortunately I accidentally slid back one of the seals over a nick. I have not test ride the bike but hopefully it will not leak.

 

[JimR]

Whenever I rebuilt the forks on my F650GS after I cleaned everything, I took some of the boss's old leg hose and ran them down each inner fork pipe. If there were any nicks the hose would snag on them. Then I would take a fine India stone and smooth the nicks out so as to not ruin the new seals. Good on you for doing it yourself!

Regards, Jim.

 

[MN Willie]

Parts plus what I would guess to be about a two hour labour job at the shop.

To the OP!

Call the local shops and ask them the "Flat Rate Time" for the Fork Seal Replacement. A Kawasaki Dealer SHOULD be able to provide you this, NO PROBLEM! They have codes that use for Warranty that have times attached. Prior or post that call, you can check "Shop Labor Rate(s)" and ask what they get to do the actual "Job".

Knowing all of these CAN be beneficial. It CAN help to ensure the Shop is honest. It CAN help to identify "Good Deals" and Shops taking SHORT CUTS" in some repairs.

Willie

Oop's.... Old posting, SORRY Guys!!!