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Fork Spring Replacement

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I went to my friend's house today to help him install some new Pella windows and we breezed through that so we decided to knock out some motorcycle maintenance tasks .

First thing we did was install some .46kg/mm fork springs on my KLX. I perused the how-to that No-Brakes wrote up and I followed it with a few differences.

I did the swap with both forks still on the bike. I just put the bike on my Goodyear bike stand (sears version below)

jack-studio.jpeg.jpg and used my tie-downs to secure the bike very tightly to the stand.

I differed from No Brakes' method in that I just removed the handlebars in order to gain access to the 30mm caps. This let me work on both sides at once.

Where he says to compress the forks after loosening the caps all the way, in order to expose the springs and the lock nut on the shaft, I used an old scissor-jack from my Ford Focus to jack up the front tire to expose both fork sides at the same time.

I used the 17mm open end wrench to hold the nut while I removed the fork caps and the spring stay washer/guide.

I placed a 15mm open end wrench underneath the 17mm nut to hold the shaft up so it wouldn't slip down into the tubes and I wouldn't have to use the magnetic telescoping rod to fish it out later.

It went pretty smoothly with only one minor issue. The .46mm/kg springs were so thick that it was a bit of a tight fit getting them installed over the plastic pieces.

Putting it back together went smoothly after I figured out how to get the heavier springs installed.

The difference in fork action is HUGE. The stock springs allowed the bike to dive far too much under any sort of front-end braking. Even rolling off the throttle caused too much fork dive, in my opinion.

Now, it's still got smooth action through the stroke, but it dives FAR LESS and the bike can actually take a jump without bottoming out. I would estimate that the brake dive is at least 95% less. It feels far more stable and steady on the street.

After that, we swapped out my friend's worn out Cheng Shin(lol) front tire for a new Pirelli MT-21 on his XT225 Serrow and repacked his front wheel bearings. If I can convince him to part with some money for springs, I'd like to help him replace his fork springs. He has 6 kids though so I may end up just buying him a set for Xmas

My next project is replacing the rear shock spring on my KLX and possibly replacing the stock tires with Kenda Track Master II out back and a Pirelli Scorpion up front.

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Sounds like you think outside the BOX , and that's a good thing. Thanks for passing along your on-hand experience with the helpful hints

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TO SWAP THE SPRINS OUT... DID YOU CHANGE THE FLUID? REPLACE SEALS? iM PLANNING ON REPLACING THE SPRINGS TOO. IM JUST MAKING A PARTS LIST NOW.

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If you just change springs its just a quick swap no other changes, 15 minutes, I think it took me.

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Good report. I have a stand/jack similiar to the one shown above, works great even sturdy enough for my street bikes.

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TO SWAP THE SPRINS OUT... DID YOU CHANGE THE FLUID? REPLACE SEALS? iM PLANNING ON REPLACING THE SPRINGS TOO. IM JUST MAKING A PARTS LIST NOW.

My bike has only 74 miles on it so all I did was swap the springs. If I were going to do a complete rebuild, I'd just send them out to Jeremy at MX-Tech. He did my YZ forks and shock and I'm really pleased with his work

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Moto Pro seems to be one of the most reliable place to get fork springs right now for the KLX's. But you could also contact Race Tech.

Dennis

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I got my springs from Race Tech. I am SERIOUSLY mechanically dis-inclined and even I found this to be a pretty simple task. I left my forks on the bike as well and just removed the handlebar to gain access. If you're just changing the springs, you don't have to do anything else or have any other parts.

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