Maintenance & Technical > KX500 Original

Front Fork Question

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dmg:
Hi All! Awesome site!

This is my first post.

I have been riding for years, had a 89 KX 250, and now have a 92 KX 500. I love everything about the bike, except the suspension. I am pretty sure the bike is bone stock. I am actually fairly sure the front tire is original (just grabbed a new one last night).

I decided I was finally going to do something about the suspension. It is mush. I took the front forks off, and was going to replace the oil, because I am sure that has never been done. I picked up some of the 7W BelRay fork oil and shock oil. When I had the forks off the bike, I tried to compress one fork just by leaning on it with my weight. I was able to push it to within 2-3 inches of the bottom. This doesn't seem right to me. It also rebounds fairly quickly, so I know the oil is bad.

The forks have never leaked. I weight around 200lbs. I ride desert and dunes.

I would love to bring in the forks and have them rebuilt by someone, like I did on my 250. That was the best money I ever spent on that bike. Now, I have more time than money, so I am trying to do it all myself. I am pretty handy, but I have never done this before.

Any thoughts?

Thanks,

Darin

jfabmotorsports.com:
Race Tech has video's on how to...fork and shock. Also, if you buy a valve kit from them you get the video free.   

http://racetech.com/

JFAB

Hillclimb#42:
 have you stiffened both adjusters top and bottom? And its still full of oil? Oil doesn't go bad as far as I know.

KXcam22:
The stock 92 comes with .39 kg/mm springs which are perfect for someone 100lbs or less.  I ended up using .46kg/mm which was about right for 200lbs.  I was unable to tune my 92 fork to acheive plushness AND no bottoming with the stock valving.  I got close with 10wt oil the .46 springs and raising the oil level to the max allowed (sorry I don't recal the level 100mm +/-).  I should have got the revalved or bought the race tech base valve.  The shock is also best with 10wt suspention fluid. Hope this helps. Cam.

jfabmotorsports.com:
This is from Race Tech 

1992 Kawasaki KX500

Type of Riding:
 Desert / Enduro / Trail
 

Gas Tank Size:
 Standard Gas Tank
 

Rider Weight (without gear): 200  lbs 

Type of Riding: Desert / Enduro / Trail
Rider Weight: 200 lbs

FRONT FORK SPRINGS
Recommended Fork Spring Rate: 0.452 kg/mm (use closest available)
Stock Fork Spring Rate: .377 kg/mm (stock)


REAR SHOCK SPRING
Recommended Rear Shock Spring Rate: 5.62 kg/mm (use closest available)
Stock Shock Spring Rate: 5.4 kg/mm (stock)

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