Fork Springs - How To ?

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chippy
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Fork Springs - How To ?

Post by chippy »

I have a set of Race Tech springs that I want to put in my 2006 KDX 200. (stock forks)
How difficult can I expect it to be? Is there a post somewhere that explains how to do it? Special tools involved?
I do have some mechanical ability and a good set of tools, so I would really like to do this myself.
Any advice?
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Chippy
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Gotanubike
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Fork Springs - How To ?

Post by Gotanubike »

Should be a piece of cake, just remove the top tap and remove / disassemble the preload spacer/washer/spring assembly(all held together by a rod for 95+ conventionals) and reassemble with your new springs. No special tools required.

This might help @2:57 mark:

1990 KDX200
Bike Profile -> http://www.kdxrider.net/forums/viewtopi ... 61#p136315
Suspension Overhaul(Shock+89-92 conventional forks) -> http://www.kdxrider.net/forums/viewtopi ... 15&t=15255
96'-98' RM125 Showa 49mm fork swap -> http://www.kdxrider.net/forums/viewtopi ... 04&t=16994
KDXrider world map! -> https://www.zeemaps.com/map?group=186158
chippy
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Fork Springs - How To ?

Post by chippy »

Thanks for the info.
So if you have a way to retrieve the dampning rod, you can actually change the springs without even removing the fork tube from the triple clamp? Has anyone tried this? I am just curious. They are not hard to remove and I should probably change the oil anyway.
MikeNZ
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Re: Fork Springs - How To ?

Post by MikeNZ »

yep you can do it easy no special tools and leave forks in trees but have to loosen off fork clamp bolts from memory, did mike about a year ago and im no mechanic. Use the service maual if you have one. from memory hooked a piece welding wire around the dampening rods to retrieve them. It is also possible to check fork oil without removing forks from trees also. Cheers.
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Re: Fork Springs - How To ?

Post by KDXGarage »

How long has it been since you changed the oil?
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chippy
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Fork Springs - How To ?

Post by chippy »

Springs are in. It was actually quite easy. The fork action feels nice, but is noisy? The springs are making noise like a flock of geese! (well , not quite that bad) They seem to be rubbing somewhere. Is this normal until they get well lubricated, or wear in a bit? Did I do something wrong? It's easy enough to take apart again if I missed something, but I hate doing things twice. Any suggestions?
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Chippy
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Re: Fork Springs - How To ?

Post by KDXGarage »

Did you leave the 9 year old oil in there? :grin:

The outside of the springs are hitting the inside of the fork tubes. A lot of people have mentioned that over the years.
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chippy
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Re: Fork Springs - How To ?

Post by chippy »

Thanks for the reply Jason.
You are correct. I did some research and the noise is a common problem. Tighten the tube to the cap seems to be the answer. I did go ahead and change the oil. It looked clean, but all of the "gunk" had settled to the bottom. It was definitely time!
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Re: Fork Springs - How To ?

Post by KDXGarage »

Great job on changing the oil. A LOT of gunk DOES indeed settle to the bottom. :blink:

Have you had a chance to ride it yet?

What is your weight in full gear and which rate springs did you go with?

Congrats on having a 2006 KDX, by the way.
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chippy
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Re: Fork Springs - How To ?

Post by chippy »

I weigh 210-215 lbs WITHOUT gear.
I used the Race Tech calculator and went by their results of .42 kg/mm.
I used Torco 5w oil and cut the spacers for 8mm of preload. I set the oil level to 4.5" from the top which is what it was at before. I am considering bumping up the rear spring rate as well.
I haven't had a chance to ride yet, the weather is not cooperating today. Maybe later this week?

She is a sweet 06 KDX200! Like new condition with an FMF Desert pipe and V-Force reeds. (and a few other goodies) I have the jetting dialed in perfect with 13x49 gearing. She RIPS ! :grin:
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Re: Fork Springs - How To ?

Post by KDXGarage »

Thanks for the info. It will be a lot better once you ride it.

Check your race sag and free sag on the spring.
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Re: Fork Springs - How To ?

Post by MikeNZ »

yep I fitted .44 racetech and they were noisey as you said, I then tightened tube to cap as you mentioned and it made no noticable difference. So just went and rode what a difference, best money spent on bike to date. i believe the noise is still there to some extent after about 1 year, it just dont really notice it anymore. I weigh about same as you and fitted 5.8 to rear also made a huge difference I got the 5.8 from motor cycle wrecker for $60 from a klx300, they are direct fit as have the same rear shock but have the 5`8 spring standard where kdx is 5.0 this was also a huge improvement. I think installing correct spring ratings should be the first mod done to any KDX, there is no better bang for your buck, its a no brainer. i'm sure you will be stoked with the performance of the new springs, enjoy.
chippy
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Fork Springs - How To ?

Post by chippy »

My original springs made the same noise, just not as noticeable.
I re-seated the springs, threaded the tube to the cap, then twisted the tubes a bit until they were as quiet as I could get them. Still some noise, but not so bad. I rode a bit yesterday evening and it is much better. I am going to play with the sag and see what that does. It does tend to push a bit on flat corners with the sag set light. My rear spring length is within tolerances with the sag set for me, but I still think a heavier spring would be that much better.
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