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Old 12-23-2006, 06:18 PM
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Default 2003 kx 250 fork oil and fork seal service

I'm working on my 2003 kx 250 right now and was looking for information on fork seal/oil replacement.FWIW I have ordered a factory manual but unfortunately it's on back order, eta unknown. I do have the proper tools but I'm completely new to the bike and KYB forks.

It states in the owners manual that fork oil level is measured with the forks collapsed, from the outer fork tube to the top of the oil(which I have done-120mm 5w from the top of the outer tube to the top of the oil) The owners manual does not say if the inner push rod needs to be fully extended,or fully collapsed when measuring fork oil height. Which one?

Any help, pictures, links etc would be greatly appreciated. Thanks!

Mike
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Old 12-29-2006, 01:01 AM
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Default Re: 2003 kx 250 fork oil and fork seal service

Hmmm, I'm really surprised that you didn't get a bite with this. We have a lot of peeps on here that should know that. Unfortunately, I'm not one of them
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Old 12-29-2006, 08:34 AM
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Default Re: 2003 kx 250 fork oil and fork seal service

The inner push rod needs to be collapsed and bled by putting your finger on it and stroking it through the travel several times until it is full. Then you can measure the oil level accurately.
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Old 01-02-2007, 12:12 AM
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Default Re: 2003 kx 250 fork oil and fork seal service

Thanks Vintage Dave
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Old 02-04-2007, 08:26 PM
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Default Re: 2003 kx 250 fork oil and fork seal service

I know this thread is a little old.

The inner pushrod needs to be fully collapsed when measuring.

Add oil fully extend it then fully collapse it about 10 times or more until it sounds like all the air is out of it. You will here weird noises and bubbling.

Measure you level. Extend the inner pushrod. Install your spring. Then put the cap on and you should be good.

I usually use an old oil seal to drive the new seal in... cut it the old one in 1/2. Sometimes I use a screwdriver but you gotta be careful

Most of the times you can remove you old oil seal and clean it up and that usually fixes the problem if dirt gets in there it can cause a leak. Simple clean will save you some cash.

Thats how I always have done it.
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