Bound Fork

Discussion specific to the various air-cooled KDX models sold in the USA
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SRRobirds
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Bound Fork

Post by SRRobirds »

Me again - working to bring a 1986 KDX200 back to life.

Planned to change the fork oil - when I drained the oil and removed the cap, I expected the bike to settle. It didn't budge. I removed the fork tubes from the triple and the left fork moves freely by hand. The right fork was bound in the extended position which I ultimately freed with significant hand pressure.

I have cycled several times fresh 5w through the binding fork and its loosening up, but not near as free moving as the left fork. I.e, after extending the left fork and releasing it, it will compress under it's own weight. The right fork stays extended and will only compress with hand pressure.

Both forks' seals seam in good shape and both forks had about the same amount of oil in them when I drained them. Tubes look perfect and I don't see any trauma on either fork bottom that might suggest the fork is bent.

Have any of you guys seen this, and if so, what's the fix if anything?

Thanks for your help with this.
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KDXGarage
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Re: Bound Fork

Post by KDXGarage »

Hi. I would want to disassemble it, to inspect the bushings and wear on the inside of the tubes.

I would assume it is bent or has internal damage.
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kdxsully
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Re: Bound Fork

Post by kdxsully »

I agree
I like turtles
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bufftester
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Re: Bound Fork

Post by bufftester »

Yep, disassemble and inspect, something is binding.
SRRobirds
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Re: Bound Fork

Post by SRRobirds »

Hi All -

You guys were right - something was binding. The picture below is the external damage to the lower leg, which I underestimated:

Image

Here is what it looked like inside the tube:

Image

And here is the bushing:

Image

I ended up finding a good used set on eBay for $50 - I'm good to go now.

Thanks for your help.
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KDXGarage
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Re: Bound Fork

Post by KDXGarage »

WOW! THAT BUSHING!

Thanks for following up on what it turned out to be.
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kdxsully
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Re: Bound Fork

Post by kdxsully »

That’s wild.
I like turtles
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