'03KDX200 wrote: ↑07:41 pm Mar 04 2020
Hello again forum. I'm going through this 2003 KDX200 that I just bought, and I want to do a fork oil change and the Shim Stack Mod. When I read through the KDX 200 shop manual on the process of changing the oil, there's quite a few special tools they want me to buy. Some things I know I don't really need. I like to save money by not buying every tool in the world, but I also appreciate not spending an extra several hours doing things the wrong way, so I don't mind buying a special tool or two either, when required. I want to ask you if these following tools are a total waste of money:
1) Fork spring holder #57001-1286
2) Fork Piston Rod Puller #57001-1298
3) Fork Outer Tube Weight #57001-1218
4) Hook Wrench #57001-1101
5) Oil Seal & Bearing Remover #57001-1058
6) Bearing Driver Set #57001-1129
I've found a lot of different videos on YouTube but they are all for some other bike and no one mentions any of these tools, and I have yet to find any step-by-step write-ups on rightside-up fork oil changes with pictures.
Congratulations. You have found that ONE GUY. I own every one of those.
Also, I used to work on other members' suspension on this site (LONG time ago)
I will give an opinion on each as it relates to your post.
1) Fork spring holder #57001-1286 (you can get by without it, I think a 16 mm open end wrench will do it, quicker and easier with the OEM or aftermarket tool)
2) Fork Piston Rod Puller #57001-1298 (you could get by without it, but the OEM tool or an aftermarket one makes it easier and neater)
3) Fork Outer Tube Weight #57001-1218 (NOT NEEDED)
4) Hook Wrench #57001-1101 (NOT NEEDED)
5) Oil Seal & Bearing Remover #57001-1058 (NOT NEEDED)
6) Bearing Driver Set #57001-1129 (NOT NEEDED)
Again, that was JUST for you and your fork oil change, not ANY generalization.
I last worked on some similar forks (KLX300R) last fall. For me, the tools that come to mind are:
rod puller (57001-1298)
fork spring holder (57001-1286)
Also, the cartridge holder tool. The OEM tool is discontinued, but hopefully Jeff Fredette still sells his tool, which I own and is great.
14 mm hex bit for the base valve assembly at the bottom
The cartridge holder tool is used to keep the cartridge from spinning during removal AND reassembly. It helps when tightening the base valve to the proper torque value. Otherwise, broom stick, trying to use the spring to keep it from spinning and other methods kinda work, but not nearly as easily or accurately.
The 14 mm hex bit tool is used to remove and install the base valve assembly.
Buy some Walmart brake cleaner to clean the parts since it is watery and not too strong. A final rinse with Brakleen or even better, Maxima Suspension Clean is great.
The tops of the base valves have the nut on top. It is peened over. One MUST file down the top a little before loosening the nuts. Feel free to read through some old threads where people snapped them off. YOU HAVE BEEN WARNED!
Torque to 25 inch-pounds, using blue Loctite.
Be mindful of how the washers stack up. Just do one at a time. If something goes wrong, you can then look at the other one to compare.
Before removing your fork tubes from the triple clamps, loosen the upper clamp bolts, then loosen the fork top caps, then loosen the lower triple clamp bolts and remove the forks.
I use some o-ring grease on the o-rings before installing. Don't put them in dry.
Blue Loctite on the base valve when installing, torque value is in the OEM manual.
Check your preload when you have it apart.
Sorry to babble! Feel free to ask questions.
Here's my favorite fork oil and suggestion:
- KYB Fork Oil.jpg (158.69 KiB) Viewed 22657 times