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Discussion Starter · #1 ·
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
 

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RideOrDieWarren
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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.
 

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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

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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+ :(
 

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Discussion Starter · #5 ·
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!
 

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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. :(
 

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The Cruising Gunsmith
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#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
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.
 

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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.

Yeah, '86-'93 bikes had these but the 2nd gen EXs dont. Kawi in their infinite wisdom decided to remove them?
 

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Discussion Starter · #9 ·
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.
 
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