Kawasaki Motorcycle Forums banner
Cancel

24K mile service questions

763 Views 8 Replies 4 Participants Last post by  taro, 
T
I am getting ready to do the 24,000 miles service on my 04 ex500.

#1. The maintenance chart recommends that I replace the caplier piston and dust seals. If I'm going to be taking the caliper apart anyway, should I go ahead and replace all of the rubber parts or is this overkill? Are there rebuild kits?

#2. The chart also recommends that I replace the master cylinder cup and dust seal. This is for the front and rear right?

#3. I'm getting ready to mess with the fork for the first time. I'm assuming that just changing to oil in the fork does not require a rebuild, correct? Is it recommended that while I have the thing apart, it should be rebuilt?

Thanks, Taro
Reply
Save
Like
1 - 9 of 9 Posts
L
1. Thats up to you. If you have the funds and the time, why not?

2. I'd do both.

3. Correct. Unless it needs it. A good thing to do also is tak ethe forks completely off the bike and clean them out thoroghly. Spray alot of cleaner in them, and then compress and rebound a few times. Dump old stuff do it again until cleaner comes out pretty clean.
Reply
Save
Like
T
Hey thanks for the feedback. Hopefully, I'll be able to get on it this weekend.
Reply
Save
Like
J
Yes, you'll need to haul the forks off the bike anyway to get all the oil out of them. FOG has a pretty good fork maintenance guide on ex-500.com

Login

Just ignore the part about tapping in your own drainer tube. The first gen EX's had them and for some reason they decided to remove them from the 94+ :(
Reply
Save
Like
T
Jimmy, thanks for the link. Great info. Hopefully, I can get motivated to crank it out. I also have to do a 150k mile service on my '98 Nissan Pathfinder. Sometimes it stinks being cheap!
Reply
Save
Like
J
Yeah, a fork rebuild/new springs/dogbones is on the list this winter. I might put some new tires on as well, depending on my budget. I don't want to repaint it because it will be my luck I'll get tboned the next day. :(
Reply
Save
Like
A
taro said:
#3. I'm getting ready to mess with the fork for the first time. I'm assuming that just changing to oil in the fork does not require a rebuild, correct? Is it recommended that while I have the thing apart, it should be rebuilt?

Thanks, Taro
Click to expand...
My KZ750 has drain plug screws at the bottom of eack front fork assembly to let you pump the oil out. I just drain it then fill it with clean oil, pump out and then refill to spec.
Reply
Save
Like
J
bountyhunter said:
My KZ750 has drain plug screws at the bottom of eack front fork assembly to let you pump the oil out. I just drain it then fill it with clean oil, pump out and then refill to spec.
Click to expand...

Yeah, '86-'93 bikes had these but the 2nd gen EXs dont. Kawi in their infinite wisdom decided to remove them?
Reply
Save
Like
T
So called progress I guess. But I guess I can't really complain too much as it hasn't given me a bit of trouble in 24k miles. Didn't get to it this weekend. Hopefully by next weekend.
Reply
Save
Like
1 - 9 of 9 Posts
This is an older thread, you may not receive a response, and could be reviving an old thread. Please consider creating a new thread.
Kawasaki Motorcycle Forums
A forum community dedicated to Kawasaki Motorcycle owners and enthusiasts. Come join the discussion about performance, modifications, troubleshooting, maintenance, off-road, touring, street bikes, and more!
Full Forum Listing
Explore Our Forums
Kawasaki Cruisers Main Lobby Kawasaki Streetbikes/Sportbikes Vintage Motorcyle Info The Mechanics Corner
Top