KLR 650 Damper Rod Holder

[G-Ray]

Hello out there: I bought an '04 KLR 650 a couple of weeks ago and nowI'm in the process of checking it over mechanically. One job I'm doing is replacing leaking fork seals.Does any one know the size of the hex that will hold the damper rod internally,for fork dissasembly? Thanks, Greg.

 

[Leon V.]

imported post

imported post

Hi G-ray, with fork on the bench, springs removed, put an old broom stick all the way to the bottom of fork. Bang on end of stick with hammer. Remove stick and measure size of hex indented on end of stick. Use a bolt of this size welded to a 3 ft. rod with a t handle on top. If you have an air gun just bang out allen bolt at fork bottom with that. Reinstall same way. Why does a `04 KLR need fork seals? They never wear out. Check tubes for bends or tiny cuts before reassembly. Toss stock springs and use Progressive Suspension springs. $80 ish. Fire in 430 cc Belray fork oil per leg if dry. Use 400 cc oil if you only drain using little hole in leg. Never run air in forks after this. 15 wt works fine. You will even have to let air out of fork during a long hot ride, it`s a cheap fork. Bye Leon

 

[G-Ray]

imported post

imported post

It's a 24mm hex in the rod. I used a length of redi-rod and a selection of nuts to find the right size. Made up a tee handle from tubing with a metric bolt in the end for the tool. Turned down a PVC pipe fitting in a lathe for a seal driver and used a pipe nipple as a slide hammer to seat the seals. The bike came with a fork brace, that I've since removed. The fork gators were partially lifted for the brace to be clamped. this may have contributed to the seal wear or maybe a pressure washer was used to clean the bike, oil was on the outside and water was in the inside. The fork brace had been hitting the bottom of the fender too. Looked trick but sure wasn't well thought out. AOK now.