KDXRIDER.NET

2002 220; I fabricated the 27 mm nut welded to a pipe holder to hold the inner rod. Works great. Now what tool do I need to fabricate or purchase to install (push in) the top bushing and seal in these forks?

I cut a piece of pvc pipe.

spl383, That's what I have in mind. I have a piece of 1 1/2", not big enough. I'll get a 2" piece tomorrow, cut a 1/4"slot length wise and use a couple of hose clamps to tighten it up on the tube. Maybe that will work.

You can use the old bushing to start the new one. Just don't go so far as to start driving the old one in on top of the new one. ...same with the seal

Motion Pro Fork Seal Driver...

some of the best $40 I ever spent

OK guys, I made a seal driver out of 2" pvc. Cut a 1/4"+ slot length wise out of a 1' long piece and put 3 hose clamps on it to collapse it to the right size for the bushings and seal. Opened it up some for the dust seal. Worked slick. I pushed in the bushing using the washer on top of the bushing. I saw that either here or on the Race Tech web site.
Now you guys recommended 1/4" preload. My old spacer would put about 7/8" preload. Before I cut the old spacer, is 1/4" preload correct? I can't come up with a pvc size to use for the spacer as was suggested.

Just saw an old post that said the 1" pvc coupler is the correct diameter to use for the fork spacer.

1" PVC won't work??

4 mm, not 6.25 mm (1/4")

Jason, 4mm is enough preload? I saw 6mm suggested and just rounded to 1/4". And, it was a 1"pvc COUPLER the other post suggested. I haven't measured one yet. I know 1" pvc pipe is too small.
Thanks for all your info.

Race Tech suggests 4 mm. I have read other tuners suggestions, and it seems the last few years, less preload is more often recommended.

Maybe it was 1.25"

https://www.google.com/webhp?sourceid=c ... pvc%20pipe

I checked the 1.25" pvc today. Too large OD. Thought I had it with 1" ridged conduit threaded unions, too large bey a hair. Think I'll just cut mine to length.

What was wrong with 1"?

Jason, I guess if I look at this stuff long enough it finally comes to me. The 1" WILL work fine. I was forgetting about the collared washers engaging the spring, not the spacer itself. All of the tubing, pvc, coduit. etc, I have been looking at, small enough to fit in the fork will work. I am missing 1 collared washer though. I think I can substitute a regular washer for the top one maybe. I looked on Bike Bandit and that washer and part # is shown on their diagram, but not supplied by them. No Kawasaki dealer close by. I will call a dealer.
Thanks for sticking with me. It just takes awhile.

No problem. I was thinking my memory was failing me.

A regular washer will work.