Fork disassembly 89 kx

[queen of spodes]

This was the first year with cartridge.  I have two sets of forks, some that are visually buggered up/rusty and a set that are pretty nice.  I have a rebuild kit with seals and bushings, and started taking apart one of the ugly legs to see what's involved.     I took the top cap off, removed the spring, and removed the fork seal retainer and seal.  There is a narrow rod inside the upper fork leg that seems to go into the lower leg.  That rod spins around freely.   The FRP fork tool I bought won't go inside the tube since the rod is in the way.   

So my next move was to use a 14mm hex socket to try loosening the bottom cap.  I got it loose where it turns, but it is not unscrewing from the fork let. 

Now the upper tube will just about come out but seems to be hanging on something.  Both the bottom cap and the fork rod spin freely without unscrewing.   

At a loss how to continue disassembling this leg.. help appreciated. 

[queen of spodes]

I went back over instructions in my Clymer manual.  They seem to skip a step from removing the fork spring, to inserting the cylinder holder tool.   My tool can't go into the hex indentation on the cylinder with the rod in place.

Anyone have a 89 service manual that could see what step I may be missing in my Clymer book?

[alward25]

use an impact gun with your 14mm socket, it will let your compression valve loosen off your dampening cartridge.  I have also used a couple of long flathead screwdrivers to hold the dampening cartridge, just need to be really careful.

Good luck

[queen of spodes]

use an impact gun with your 14mm socket, it will let your compression valve loosen off your dampening cartridge.  I have also used a couple of long flathead screwdrivers to hold the dampening cartridge, just need to be really careful.

That's how I loosened the valve in the first place - it just spins freely around.   I'll see if I can find a long screwdriver like you mentioned.

[queen of spodes]

Following up in case anyone else runs into this.  I ordered a Freddette Racing Products fork damper rod tool.  It can be ordered here (as of April 2014 it was 24.95 + shipping).  http://www.frpoffroad.com/FRP-Fork-Damper-holder-detail.htm?productId=-153479&browse=-21595&shopBy=-4056&catalogid=-1039&referrer=http://frpoffroad.com/catalog/details.aspx?ProdID=9

It's labeled as "FRP Fork Damper holder"

Description
FRP fork Holder tool will help take all KDX forks apart. Will fit all 200/220's 1986-2006 except the 1993-1994 forks.  [and 1989 KX125, KX250 and KX500 - me]

Part Numbers
Part #   Description   Price   
01-029   FRP fork Damper tool. fits most KDX's. Also will fit bikes with conventional forks that requires a 27mm or 30mm allen to hold damper rod.   $24.95


The FRP fork tool worked fine but I did have to clean up some weld overspray with a 1/2" drill bit.  



Have to remove this nut before the damper rod holding tool will slide down over the rod.








Next I put my breaker bar with 14mm hex bit on the floor, stood the fork leg on that, then used an impact wrench to pop the damper rod loose with the FRP tool.  I could have used a regular wrench.. it came off real easy.




Now to find the smaller bushing on the damper rod... which wans't included in the All Balls bushing kit.

[queen of spodes]

Anyone know where I can get this bushing?  Looks like it is not available individually and I don't feel like spending $140 x 2 for new cylinders just to get the bushing.


http://www.partzilla.com/parts/search/Kawasaki/Motorcycle/1989/KX125-G1+KX125/FRONT+FORK/parts.html#uloc9

[Foxx4Beaver]

that might be a tough one, as every OEM Kawie supplier has it listed as "Not Shipping", or aka, discontinued.
Maybe you can find one on e-bay NOS, or maybe find a cheap set of 89 forks for sale as parts.

[Foxx4Beaver]

this appears to be what you need, possibly....

http://www.ebay.com/itm/NOS-OEM-NEW-KAWASAKI-1989-KX125-KX250-KX500-FRONT-FORK-BUSHING-92028-1570-/271155720195?pt=Motorcycles_Parts_Accessories&hash=item3f2223f003&vxp=mtr

[queen of spodes]

That's the fork bushing.  I have those already.   I needed the damper rod bushings which are a lot smaller than the fork bushings.   Lucky for me, I found a set over at Race Tech: http://racetech.com/ProductSearch/1/Kawasaki/KX125/1989

FKRB 125 P    KYB ROD BUSHING 12.5x16x5 (PR)    $15.99

Order them a few minutes ago.

Can't believe how nasty the fork oil was on both sets of forks (I have two - one nice pair and one for parts).  

[Foxx4Beaver]

I found a set over at Race Tech:

cool, good to know.

[sandblaster]

That is good to know, I thought you were out of luck on that one.
Funny, I just signed up to be a Race Tech dealer late last week.

[Foxx4Beaver]

Funny, I just signed up to be a Race Tech dealer late last week.

that's also good to know!

[queen of spodes]

Update - the bush that Race Tech sent is the correct part, but is too small.   I wasn't paying attention to the actual size listed and keyed on the part name "cylinder bushing". 

Theirs is 16 OD, 12.5 ID and 5 wide, and is a plastic material.

Mine is 41 OD, 40 ID, and 5 wide, and is copper with teflon on the outside.

The teflon on my bushings is pretty worn down, lots of scratches and I wouldn't feel right putting the forks back together with these installed.

So.. back to the drawing board. 

[queen of spodes]

Nobody makes the bushing I need anymore.  Decided to reuse the best 2 of 4 and run with it.

This leads me to my next weird problem.   When taking things apart I carefully bag or cup everything, for easier reassembly.   Out of four fork legs, I only have one of these on the damping rods:



I'm not sure if I can run without these things, or if I need to play more fork roulette on Ebay to try and get another one.  

Also weird -- this little spring thingamajig isn't showing on the parts diagram:
http://www.partzilla.com/parts/search/Kawasaki/Motorcycle/1989/KX125-G1+KX125/FRONT+FORK/parts.html

[queen of spodes]

Got the forks back together last night.   They feel pretty nice when compressing them against the shop floor.    I regret skipping replacement of that inner cylinder bushing, but I couldn't find a reasonably priced replacement.   Someone on Ebay has this part at $20 x 2.   The ones I reused were in good shape, so I'm running with them.