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Discussion Starter #1
1993 Ninja 600c w/ 9,000 miles

I just replaced my fork seals today. It seemed very straight-forward. I did what the manual said and put them back the same way I took them apart. However, when I was finished, I sat on the bike at pushed the bike up and down a few times. It almost sounds like the forks are bottomoing out. It makes a little contact noise by where the forks mount to the handlebars. like they are pushing up into my handlebars.

I checked and the upper and lower clamps are tight. I dont know what it could be? Not enough fork oil? I put in exactly what the manual said. Anybody know what this is?
 

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Check your steering head bearing. 15 weight might be too heavy but thats a long shot.

I'm not 100% on my fork theory but if you have too much oil you'd be compressing the air space too hard so that might be something else as well? Someone else who knows more will know for sure.

For now though, check those bearings.
 

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Discussion Starter #5
As far as I can tell, the stearing head bearing is fine. I didnt mess with it during the fork removal and it seems to be working fine. My manual doesnt have a steering head bearing though (it is called a steering stem bearing). Is that the same thing? I appreciate the help, any other ideas?
 

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No, you shouldn't hear any kind of knocking. There should be lots of travel left even when you're rocking the bike back and forth as hard as you can.

Are the springs progressively wound? If they are, did you insert them the same way they came out? (I don't even know which way is the right way lol)
 

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Discussion Starter #9
No, you shouldn't hear any kind of knocking. There should be lots of travel left even when you're rocking the bike back and forth as hard as you can.

Are the springs progressively wound? If they are, did you insert them the same way they came out? (I don't even know which way is the right way lol)
I did notice they were in a certain way, and I did take notice to put them back in the same way. I believe it was the tighter wound side down.

Does anyone know anything about the ESCS suspension? Little black box on the right front fork leg that deals with suspension stiffness. It had a wire connected to it that I didnt to disconnect b/c it seemed to go way inside the rear of the bike. I kind of stretched it a little. Possibly I unhooked the connector? Could that cause it?
 

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Any chance there is a misaligned spacer?

Any chance you are hearing the side of the spring hit the inside of the tube?

Are you locking the front brake when you do this? On some KDX's with a floating front rotor, some have mistaken a noise from the rotor as being from the forks, is why I ask.
 

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Discussion Starter #12
Herk - I am 99% sure I installed the damper assembly correctly. I used a manual and I did one at a time, so I could check on the second to make sure I put the first one back together correctly. Let me try to remember. Heres the order.

-put the spring on the piston/cylinder unit
-dropped the spring/piston/cylinder unit into the top of the inner fork tube
-put the base on to piston/cylinder unit (with washers on right fork)
-put the whole inner fork tube with cylinder unit and base into the outer fork tube
-bolted inner and outer fork tubes together
-finished off the seals, then put in oil, spring, and spacer/plug/alignment according to manual.

KDXGarage - It definitely could be something misaligned. Because its not a really pronounced sound. I can slightly hear and feel it coming from the top of the fork tube (underneath the handlebar bolts). It does not sound like bottoming out, I would imagine that would be a pretty loud hit and it would resinate more near the bottom tube. The best way I can describe it is there is a little man inside the fork tube hitting the top with a tiny little hammer each time I press down on the handlebars. Like this guy-->:roll: Heres the way I put the spacer in

Threaded plug
spacer
alignment washer
spring

I believe that is correct.
 

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I clicked on your link and saw that the forks are conventional (right side up, not upside down). From your description, it sounds like they are cartridge style forks. Is that correct?

Is the black box an anti-dive mechanism??
 

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Discussion Starter #14
yes, they are cartridge style.

The little black box is the ESCS control (electronic suspension control system). It lets you choose between 1,2,&3. (soft, moderate, stiff) suspension. I left it where it was. I believe on 1.
 

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Thanks for letting us know. I am glad to hear that you got it worked out.
 
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