Fork Service...

[Enduro_Mayhem]

Hi everyone

Apologies if this topic's been covered a million times before - I've tried to use the 'search' facility but it's not throwing anything up!

Is there a guide to performing a fork service (oil, seals, strip and rebuild), that anyone knows of? The seals on my '94 220 are shot and the oil's sure to be well past its best after goodness knows how many years of use!

Thanks in advance for any help/guidance.

[CoronasAndChips]

http://kdxrider.net/Kayaba.htm

Sent from my SCH-I535 using Tapatalk 4 Beta

[CoronasAndChips]

Or YouTube or search the net for a pdf.

Sent from my SCH-I535 using Tapatalk 4 Beta

[KDXGarage]

What country are you in? Thanks.

[bufftester]

I would love to just see a '94 220 Must have been an early pre-pre-production model

[KDXGarage]

Come on, now. Didn't you ever wonder why the 1997 USA KDX220R is labelled KDX220-A4?? That is because it came out in 1994, just not in the USA.

He has a KDX220-A1.

>>>>>>>http://japan.webike.net/products/9724350.html

[Enduro_Mayhem]

Yup... Jason is absolutely spot-on!

It's a Japanese market KDX 220-A1, manufactured in April '94, as verified by Kawasaki Motors UK. I imported it into the UK and registered it in September 2012.

Thanks for the replies and guidance all... really appreciate it.

[KDXGarage]

I do all right sometimes.

Remember to take the base valve out of the bottom and remove the seal circlip before separating the tubes. Pour a large pot of boiling water over the seal area before separating the tubes. It will help save the bushings, and make the tubes easier to separate. I would say to go ahead and replace them due to age and wear anyway.

Here is a picture I took of the forks taken apart.

[Enduro_Mayhem]

Thanks again Jason.

You do far better than all right... the picture you've attached is going to save me loads of grief, too.

Top man!

[KDXGarage]

You are welcome. Good luck with it.

[uggski]

I have a 94 KDX UK model.

Here's a picture.

[KDXGarage]

Thanks for the picture. Are the blue forks stock?

[uggski]

Yes. I believe they were. I think they are the same forks as the 94 KDX200 E6.