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So I pulled the stock forks on my 2001 KDX220 and rebuilt them with the appropriate springs.
I'm now going to reassemble and after checking the torque values, I've got a couple questions and wanted to know what others were doing.

The front axle torque is 65 ft-lbs. This is crazy tight and once tightened to that, my wheel definitely feels like it has drag to it when spinning it by hand. Is everyone torquing to this value and experiencing the same thing?

As for the torque specs on the triple clamp pinch bolts.
For the upper I am seeing 14.5 ft-lbs, but some are saying 10 ft-lbs.
For the lower I am seeing 18 ft-lbs, but some are saying 12 ft-lbs.

I believe the 30mm nut on the steering stem is 33 ft-lbs and it looks like everyone has been consistent on that?

Just curious as to what specs everyone is following. The axle tightness is what made me immediately question everything.

Thanks guys.

Front Axle 65lbs
Fork upper 14.5, lower 18
Stem head nut is 33

65lbs is a lot so back it off to 55 and see if it feels better. It ain't gonna fall off [emoji51]


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stock values, just make sure everything is lined up properly

Something must be misaligned or your torque wrench is out of calibration. I use stock value of 65 lbs all the time with mo issue.

When doing up the steering head nuts on my bike, after first tightening up the lower nut, I found when then tightening up the uppermost nut, there was a very noticeable drag on the bearing. I found I had to slacken up a little on the lower nut, then torque up the upper nut.

I am attributing this to the thread clearance between the nuts and steering stem. When tightning up the lower nut, the thread flank contact is "up", and when then tightening up the upper nut, the thread flank contact for the lower nut changes to "down", causing increased force against the steering head bearing.

Just my own observation and conclusion, but thought others might find this interesting.

Front end back together.
Went to replace rear bearings and noticed the hub is cracked...great...unreal.
Every time I touch this thing I find something else which was neglected by the p/o...

Ugh. Bad luck on that.

Definite bad luck.
eBay is turning up nothing at all either.

Do a part number search. Many different Kawasakis use the same rear hub. Then check eBay and other sources for rear wheels or hubs from all the bikes that use that same part number hub.

In my case, I found a guy on Craigslist parting out an E series KDX 200 and so was able to get a spare wheel that was a direct fit on my H series.