Fork rebuild - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 18 (permalink) Old 09-22-2009, 04:13 AM Thread Starter
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Fork rebuild

Because of a recent crash, my right fork is bent.....

I was curious if anyone else here has rebuilt one or both forks....if so, do you have any suggestions over that offered in the Clymer, Kawi or Haynes manuals?

Anything you've found that works better/easier than part of what's in those manuals? Any mistakes you may have found in the rebuild descriptions in any of those manuals? Or "shortcuts" that you've found that you care to offer on this procedure?

Besides Ron Ayres, where else can I get good (or even better) prices on Kawi fork parts (besides Ebay)?

Thanks in advance for any feedback you can offer....

'05 VN750



For other bike pix & mods, go to:
http://s1203.photobucket.com/albums/...k/VN750%20pix/

Last edited by theauhawk; 09-22-2009 at 04:31 AM.
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post #2 of 18 (permalink) Old 09-22-2009, 04:34 AM
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I just finished rebuilding vulcan89's forks and I used the same process when I did mine. It's totaly different than the books or any process you have seen here. It's faster and a hell of alot easier. Give me a couple of days to post it.

What parts do you need? Cheap cycle parts has good prices.

http://www.cheapcycleparts.com/Street.aspx


85 VN700 "Old Yella"

REBUILT ENGINE
CUSTOM PAINT
VANCE & HINES CRUZERS
EAR SHAVED AND RE-JETTED W/K&N'S
DUNLOP ELITE K591 FRONT & REAR
VOLTMETER
SYNTHETIC BRAKE FLUID
SYNTHETIC OIL & GEAR LUBE
PLEXISTAR 2 WINDSHIELD
SPLINES LUBED
ACCT'S GREASED W/TOC SPRINGS
COASTERD
LEATHER SADDLE BAGS
LEATHER TOOL AND ROLL BAG
PICKUP COILS GAPPED AT .018"
NGK CAP, WIRES, IRIDUMS
BARNETT FRICTION PLATES & SPRINGS
CUSTOM GRIPS, MIRRORS, LEVERS
ORIGINAL STATOR & R/R 14.5v
DEKA MF AGM ETX15L

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Last edited by lance328; 09-22-2009 at 04:39 AM.
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post #3 of 18 (permalink) Old 09-23-2009, 12:10 AM Thread Starter
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Thanks, Lance....

If you could post your preferred fork rebuild, I'm sure it would be universally appreciated by the Forum.

To answer you other question: as a bare minimum, I need the inner and outer fork tubes, as well as any oil seals.

Not sure what else I'll need until I get inside the damaged fork.

'05 VN750



For other bike pix & mods, go to:
http://s1203.photobucket.com/albums/...k/VN750%20pix/
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post #4 of 18 (permalink) Old 09-23-2009, 12:40 AM
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Quote:
Originally Posted by theauhawk View Post
Thanks, Lance....

If you could post your preferred fork rebuild, I'm sure it would be universally appreciated by the Forum.

To answer you other question: as a bare minimum, I need the inner and outer fork tubes, as well as any oil seals.

Not sure what else I'll need until I get inside the damaged fork.
To save some money I would buy the tube and slider off Ebay. Below are links for both new, and go to kaw and get the seals. I would offer him $150.00 for the slider.

TUBE

http://cgi.ebay.com/ebaymotors/Kawas...Q5fAccessories


SLIDER

http://cgi.ebay.com/ebaymotors/KAWAS...Q5fAccessories


85 VN700 "Old Yella"

REBUILT ENGINE
CUSTOM PAINT
VANCE & HINES CRUZERS
EAR SHAVED AND RE-JETTED W/K&N'S
DUNLOP ELITE K591 FRONT & REAR
VOLTMETER
SYNTHETIC BRAKE FLUID
SYNTHETIC OIL & GEAR LUBE
PLEXISTAR 2 WINDSHIELD
SPLINES LUBED
ACCT'S GREASED W/TOC SPRINGS
COASTERD
LEATHER SADDLE BAGS
LEATHER TOOL AND ROLL BAG
PICKUP COILS GAPPED AT .018"
NGK CAP, WIRES, IRIDUMS
BARNETT FRICTION PLATES & SPRINGS
CUSTOM GRIPS, MIRRORS, LEVERS
ORIGINAL STATOR & R/R 14.5v
DEKA MF AGM ETX15L

Best Auto/Moto Insurance | Motorcycle Protection Today | FREE Trade-In Quote

Last edited by lance328; 09-23-2009 at 12:45 AM.
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post #5 of 18 (permalink) Old 09-23-2009, 09:03 PM Thread Starter
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Based on what I've seen over at the Ron Ayers website, the figures given in the links above are good prices--thanks.......!

Once inside the damaged fork--how do I verify which parts are in fact bad (besides the seals) and in need of replacement....?

'05 VN750



For other bike pix & mods, go to:
http://s1203.photobucket.com/albums/...k/VN750%20pix/
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post #6 of 18 (permalink) Old 09-24-2009, 08:56 AM
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Quote:
Originally Posted by theauhawk View Post
Based on what I've seen over at the Ron Ayers website, the figures given in the links above are good prices--thanks.......!

Once inside the damaged fork--how do I verify which parts are in fact bad (besides the seals) and in need of replacement....?
I highly doubt you have internal damage, can you post a pic of the fork?


85 VN700 "Old Yella"

REBUILT ENGINE
CUSTOM PAINT
VANCE & HINES CRUZERS
EAR SHAVED AND RE-JETTED W/K&N'S
DUNLOP ELITE K591 FRONT & REAR
VOLTMETER
SYNTHETIC BRAKE FLUID
SYNTHETIC OIL & GEAR LUBE
PLEXISTAR 2 WINDSHIELD
SPLINES LUBED
ACCT'S GREASED W/TOC SPRINGS
COASTERD
LEATHER SADDLE BAGS
LEATHER TOOL AND ROLL BAG
PICKUP COILS GAPPED AT .018"
NGK CAP, WIRES, IRIDUMS
BARNETT FRICTION PLATES & SPRINGS
CUSTOM GRIPS, MIRRORS, LEVERS
ORIGINAL STATOR & R/R 14.5v
DEKA MF AGM ETX15L

Best Auto/Moto Insurance | Motorcycle Protection Today | FREE Trade-In Quote
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post #7 of 18 (permalink) Old 09-24-2009, 08:58 AM
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Quote:
Originally Posted by lance328 View Post
It's totaly different than the books or any process you have seen here.
Come on Lance, we're all dying to hear about this.

Scheherazade
'86 VN750
MF Battery, Iridium Plugs, RR relocated, Voltmeter, 170/80/15 Kenda Kruz rear tire, DIY Samsonite hard bags, DIY shaved seat with Beaded seat pad ('cause that's how I roll) and the dreaded STATOR CHANGE.

Shining Black Bess '86 VN750, retired for parts after a fried stator and being knocked (kee-runch) in her parking spot.
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post #8 of 18 (permalink) Old 09-24-2009, 05:18 PM Thread Starter
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I've ordered the fork inner tube, per your suggestion/link above. Thanks again for finding this link on Ebay......!

But I'm not fully convinced that I need to replace the bottom (outer) tube (aka, slider) yet. If it's not obviously bent as well, and there are no cracks anywhere on it--can I still use the one I've got? What's a good reason to get the bottom tube/slider, if the current one looks ok....

You asked for a photo. The bike is currently over at a friend's, and it will be sometime during the weekend before I can shoot a pix or two and post.

'05 VN750



For other bike pix & mods, go to:
http://s1203.photobucket.com/albums/...k/VN750%20pix/
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post #9 of 18 (permalink) Old 09-24-2009, 07:29 PM
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Quote:
Originally Posted by theauhawk View Post
I've ordered the fork inner tube, per your suggestion/link above. Thanks again for finding this link on Ebay......!

But I'm not fully convinced that I need to replace the bottom (outer) tube (aka, slider) yet. If it's not obviously bent as well, and there are no cracks anywhere on it--can I still use the one I've got? What's a good reason to get the bottom tube/slider, if the current one looks ok....

You asked for a photo. The bike is currently over at a friend's, and it will be sometime during the weekend before I can shoot a pix or two and post.
If your slider has no damage then you do not need to replace it. Get oil and dust seals for both forks and 1 litre of 15w fork oil, you will need to do both forks. You need to make sure both have the same weight oil and same amount, or it will cause handeling problems.


85 VN700 "Old Yella"

REBUILT ENGINE
CUSTOM PAINT
VANCE & HINES CRUZERS
EAR SHAVED AND RE-JETTED W/K&N'S
DUNLOP ELITE K591 FRONT & REAR
VOLTMETER
SYNTHETIC BRAKE FLUID
SYNTHETIC OIL & GEAR LUBE
PLEXISTAR 2 WINDSHIELD
SPLINES LUBED
ACCT'S GREASED W/TOC SPRINGS
COASTERD
LEATHER SADDLE BAGS
LEATHER TOOL AND ROLL BAG
PICKUP COILS GAPPED AT .018"
NGK CAP, WIRES, IRIDUMS
BARNETT FRICTION PLATES & SPRINGS
CUSTOM GRIPS, MIRRORS, LEVERS
ORIGINAL STATOR & R/R 14.5v
DEKA MF AGM ETX15L

Best Auto/Moto Insurance | Motorcycle Protection Today | FREE Trade-In Quote
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post #10 of 18 (permalink) Old 09-24-2009, 10:02 PM Thread Starter
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Lance: since you've "been there, done that" with the forks--what internal fork parts/gaskets/rings (if any) will "fail" when either fork is disassembled--and will need replacing (besides the dust and oil seals you've already mentioned)..........???

'05 VN750



For other bike pix & mods, go to:
http://s1203.photobucket.com/albums/...k/VN750%20pix/
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