fork rebuild question. - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 8 (permalink) Old 08-31-2014, 02:07 PM Thread Starter
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fork rebuild question.

ok, just got done replacing the fork oil and dust seals..

Now, I can bottom out the forks... previously I couldn't.

fork oil level at spec, used 15w.

springs are original oem (I aint replacing them, unless someone has some free progressives, that leaves me at original ride height). I doubt these are the problem.

on reassembly, I had some confusion as to exactly the order of the parts at the bottom of the outer tube.. specifically the cylinder base, spring (small spring) and valve. I *think* these are in the right way, as I am able to tighten the allen bolt on the bottom of the outer tube properly.

also, i *think* the left and right forks where different in that regards... but I cant be sure of that.

what did I miss?? or screw up?

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post #2 of 8 (permalink) Old 09-01-2014, 09:01 AM
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post #3 of 8 (permalink) Old 09-01-2014, 09:58 AM Thread Starter
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that just the exploded diagram of the fork.

I have more than 1 copy of it.

I have also watched roaches video (many times), and read/studied the sticky in the suspension section.

Roaches video is the most clear as to how it all goes together, and between that and my service manual thats what I went with to put it together.

I did take it for a ride today, about 8 miles total (just to the closest party store, needed to fill my backpack with munchies and beverages), and it seems ok. my only concern at this time is that I can now bottom the forks, where as I couldnt before.

I may think of a slightly longer spacer and see if the added preload helps any. Im a pretty heavy guy, and just sitting on the bike compresses suspension significantly

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post #4 of 8 (permalink) Old 09-01-2014, 11:53 AM
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Forks shouldn't bottom out unless the springs are shot or there's something missing. (Of you hit a real big bump) Your stock spacers should measure about 9-3/8" long (I think)
Not sure the length on the stock springs..
Heavier fork oil should just make them slower to bottom, not prevent them.

Seems you are saying they only did this after you replaced the seals, so it sounds like something isn't right now.

You can try adding another inch of preload by just adding a stack of fender washers to the top of each spring. Do you know how many ounces of fork oil you put in?

Again should take s lot if effort to bottom a fork, so something ain't right.

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post #5 of 8 (permalink) Old 09-01-2014, 12:09 PM Thread Starter
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I dont know how many oz's of oil, I measured how much was in the tubes with a ruler, and went by spec in the manual.

when I lean forward on the bars (bike not moving), I can compress them, but not bottom them. If I lock the front brake, and give a good forward/downward thrust on the bars, they will bottom.

I agree, new heavier oil should make the forks slower to compress, and the movement of the forks is smooth and not jerky at all.

guess I am gonna have to get more fork oil, and take them apart again, and see if something is amiss.

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post #6 of 8 (permalink) Old 09-01-2014, 01:05 PM
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I strongly reccomend installing a set of Progressive fork springs.... But yes, they are about 100 bucks.

Just sounds like the springs on the bike are worn out and the progressive springs are a bit stiffer. They are also longer (require you to cut the spacers down)
I think I put 11oz of 15w fork oil in each leg on my bike... But I didn't take them completely apart... But did put in the Progressive springs.

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post #7 of 8 (permalink) Old 09-01-2014, 06:24 PM
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the manual calls for 12.5 oz of oil per side I went with 13 oz per side
I am 250lbs and on hard hits I can bottom the forks out but other than that they seem fine

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post #8 of 8 (permalink) Old 09-03-2014, 07:35 PM
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i would read Lance 328's post in Sep 2009 on fork rebuilds. 12.5 oz of oil. I rebuilt my forks recently and they are tight and have much more resistance to compression. Something must be amiss on your bike at the moment.

I hope you get it figured out as forks should not bottom out from normal riding...

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