Rebuild KYB Open Chamber Forks Without Special Tools

Introduction

This tutorial will guide you through the process of rebuilding KYB open chamber forks without the need for special tools. While using the correct tools is recommended for optimal results, you'll learn how to effectively complete the task using common items and some innovative alternatives. This guide is essential for motorcycle enthusiasts looking to maintain their bikes efficiently and cost-effectively.

Step 1: Gather Your Materials

Before beginning the rebuild, ensure you have the necessary materials and tools. Here’s what you need:

• KYB open chamber fork rebuild kit
• 14mm Allen socket
• Fork seal bullet
• Fork seal driver
• Fork oil level tool
• Maxima 5W fork oil
• ProX fork and dust seal kit
• ProX fork bushing kit
• 1 1/4 inch closet rod (as a makeshift tool)

Practical Tips

• Purchase the parts from trusted suppliers like Rocky Mountain ATV/MC.
• Ensure you have a clean workspace to prevent contamination.

Step 2: Remove the Forks from the Motorcycle

Follow these steps to safely detach the forks:

1. Place the motorcycle on a stable stand.
2. Remove the front wheel and brake calipers.
3. Loosen the fork clamps on the triple tree.
4. Carefully slide the forks out of the clamps.

Common Pitfalls to Avoid

• Do not force the forks out as this may damage the clamps or the forks themselves.
• Ensure the motorcycle is securely supported during this process.

Step 3: Disassemble the Forks

Now that the forks are removed, disassemble them:

1. Use the 14mm Allen socket to remove the bottom bolt of each fork.
2. Drain the old fork oil into a suitable container.
3. Pull out the inner tube from the outer tube.

Practical Advice

• Inspect all parts for wear or damage as you disassemble.
• Clean all components with a suitable solvent to remove old oil and dirt.

Step 4: Replace Seals and Bushings

Replacing the seals and bushings is crucial for proper function:

1. Remove the old fork seals using the fork seal driver.
2. Install new seals from the ProX fork and dust seal kit.
3. Replace fork bushings if worn.

Tips for Installation

• Use a fork seal bullet to protect the new seals during installation.
• Ensure seals are seated properly to prevent leaks.

Step 5: Reassemble the Forks

Once seals and bushings are in place, reassemble the forks:

1. Insert the inner tube back into the outer tube.
2. Tighten the bottom bolt securely using the 14mm Allen socket.
3. Fill the forks with Maxima 5W fork oil to the recommended level using the fork oil level tool.

Important Note

• Refer to the manufacturer's specifications for the correct oil level and type.

Step 6: Reinstall the Forks on the Motorcycle

With the forks rebuilt, it’s time to reinstall them:

1. Carefully slide the forks back into the triple tree.
2. Tighten the fork clamps to the specified torque.
3. Reattach the front wheel and brake calipers.

Final Checks

• Ensure all components are torqued to the manufacturer’s specifications.
• Check for any unusual noises or leaks after the rebuild.

Conclusion

Rebuilding KYB open chamber forks can be done effectively without special tools by following these steps. Always prioritize safety and ensure everything is properly installed to maintain the performance of your motorcycle. As a next step, consider tuning your forks based on your riding style for enhanced performance. Happy riding!