Rebuilding Kat forks

dgyver · July 23, 2007, 05:40:50 AM

Sunday was bike work day. I finally got back into working on my bikes after a multiple week hiatus.

One of the seals on my 97 was leaking bad enough I did not want to ride it. I had never rebuilt forks before and Ben (ben2go) had offered his help. Since he was going to rebuild his Kat forks, it was a prime opportunity for both of us.

Not know what all tools were required, as compared to the GS forks, we found out that the 89-97 Kat forks do not require any special tools to be fabricated. Just a 24mm (15/16" worked just fine) wrench to remove the fork caps, a 6mm allen wrench for the lower bolt holding the cartridge in place, and a 10mm wrench to remove a drain plug. A few other common tools were used as well, like a screwdriver to remove the dust seals and snap rings that hold down the actual seals. A fork seal driver was made out of a piece of PVC pipe, better than the screwdriver the previous rebuilder had used (no wonder they leaked). A better driver is on my list to buy for the next set.

These are a very simple design. Good thing since I have 2-3 more sets to rebuild.

Jay_wolf · July 23, 2007, 05:51:00 AM

My kat seals are soooooooo bad ,ive bought some new ones ,but i cant fit them , i dont have a clue , did u find it hard to do? then again your a wrencher

nastynate6695 · July 23, 2007, 07:35:10 AM

hey d .... on the kat forks...is there a potential for the assembly inside the tube to spin like the gs does from time to time. I know when the gs assembly does it you have to fabricate your own tool to stick down in there and catch it.

dgyver · July 23, 2007, 09:29:47 AM

Quote from: Jay_wolf on July 23, 2007, 05:51:00 AM
My kat seals are soooooooo bad ,ive bought some new ones ,but i cant fit them , i dont have a clue , did u find it hard to do? then again your a wrencher

As for complexity, this was a very easy rebuild. I had never been inside forks before and would not hesitate to do it again. There are very few parts. All I had to go by was an exploded view from BikeBandit.com. Just make sure you install the washer before the fork seal. It is a pain to remove a good seal.

dgyver · July 23, 2007, 09:31:04 AM

Quote from: nastynate6695 on July 23, 2007, 07:35:10 AM
hey d .... on the kat forks...is there a potential for the assembly inside the tube to spin like the gs does from time to time. I know when the gs assembly does it you have to fabricate your own tool to stick down in there and catch it.

No. The drain screw also works as a pin to lock into a notch in the lower spacer. The cartridge has a D shaped end which locks into the lower spacer. Nothing can turn.

ben2go · July 23, 2007, 09:46:31 AM

Quote from: dgyver on July 23, 2007, 09:29:47 AM
Quote from: Jay_wolf on July 23, 2007, 05:51:00 AM
My kat seals are soooooooo bad ,ive bought some new ones ,but i cant fit them , i dont have a clue , did u find it hard to do? then again your a wrencher

As for complexity, this was a very easy rebuild. I had never been inside forks before and would not hesitate to do it again. There are very few parts. All I had to go by was an exploded view from BikeBandit.com. Just make sure you install the washer before the fork seal. It is a pain to remove a good seal.

+1 on the seal.If anyone is going to attempt to rebuild the Katana forks lay your parts out in order.Maybe you won't forget the washer like I did.Sorry again for that dgyver.
As dgyver stated earlier,NO SPECIAL TOOLS ARE NESSASARY.You don't have to go inside the forks to remove the cartridge/valve.There is a 10mm bolt on the bottom of the fork leg that indexs the internals and holds everthing while you remove the bolt in the bottom of the fork leg.

Dgyver,when you are ready to rebuild another set of Kat forks let me know.If you're up to it,we could do a step by step write up with pics.

Oh yea, WE ARE THE KAT FORK MASTERS.

The Buddha · July 23, 2007, 09:57:42 AM

OK it took you 2 working all weekend to do this

Yea ... larger forks actually are easier. My worst fork was the damn KZ440 like the 4mm diameter dont laugh, no bigger than your finger ...
Eliminator and vulcan and GS were all easy - OK easier.
BTW showa is better than kayaba too.
Cool.
Srinath.

ben2go · July 23, 2007, 10:08:15 AM

Quote from: seshadri_srinath on July 23, 2007, 09:57:42 AM
OK it took you 2 working all weekend to do this
Yea ... larger forks actually are easier. My worst fork was the damn KZ440 like the 4mm diameter dont laugh, no bigger than your finger ...
Eliminator and vulcan and GS were all easy - OK easier.
BTW showa is better than kayaba too.
Cool.
Srinath.

If we had just rebuilt the forks and cut out the talking and meticuless cleaning,it would have taken bout 2 to 3 hours.

I'd rather rebuild Kat forks than GS,but I'll do what ever makes the money with no complaints. BTW I helped dgyver do his for the learning experience.Twas fun.

dgyver · July 23, 2007, 10:28:08 AM

All weekend? Who said that? It was only Sunday.

Probably had 4 hours total in removal from bike, rebuild (including 1/2 hour of mis-assembly, looking for seals, fabricating a driver, and reassembly on bike with a little BS'ing along the way. So yeah, 2-3 hours off bike would be about right.

A write-up w/ pics would not be difficult to do. I forgot to take a reference pic of the spring. I will have a driver before next rebuild, and maybe even make an oil level gauge.

ben2go · July 23, 2007, 10:36:07 AM

Quote from: dgyver on July 23, 2007, 10:28:08 AM
All weekend? Who said that? It was only Sunday.

Probably had 4 hours total in removal from bike, rebuild (including 1/2 hour of mis-assembly, looking for seals, fabricating a driver, and reassembly on bike with a little BS'ing along the way. So yeah, 2-3 hours off bike would be about right.

A write-up w/ pics would not be difficult to do. I forgot to take a reference pic of the spring. I will have a driver before next rebuild, and maybe even make an oil level gauge.

I'm in.Lets do it.

Jay_wolf · July 23, 2007, 01:03:17 PM

good work ben

and Dgyver

The True Kat Fork Rebulders ! lol

nastynate6695 · July 23, 2007, 02:41:44 PM

"As for complexity, this was a very easy rebuild. I had never been inside forks before and would not hesitate to do it again. There are very few parts. All I had to go by was an exploded view from BikeBandit.com. Just make sure you install the washer before the fork seal. It is a pain to remove a good seal."

you know if you ever need an exploded view there is a great website that has everything suzuki http://www.alpha-sports.com/Parts/SuzLFrame.html then there is this one i use from time to time to check other models http://www.dansmc.com/shopmanual2.htm

dgyver · July 23, 2007, 03:20:56 PM

Quote from: ben2go on July 23, 2007, 10:36:07 AM
I'm in.Lets do it.

I just ordered an adjustable fork seal driver. Once it comes in we can figure out a good time to do this.

ben2go · July 23, 2007, 10:37:43 PM

Quote from: dgyver on July 23, 2007, 03:20:56 PM
Quote from: ben2go on July 23, 2007, 10:36:07 AM
I'm in.Lets do it.

I just ordered an adjustable fork seal driver. Once it comes in we can figure out a good time to do this.

ABSOLUTELY NO PROBLEM

I need seals and dust seals will you grab some for me also.95 Kat forks of course.I'll happily repay you.

dgyver · July 25, 2007, 04:10:29 PM

Quote from: ben2go on July 23, 2007, 10:37:43 PM

ABSOLUTELY NO PROBLEM

I need seals and dust seals will you grab some for me also.95 Kat forks of course.I'll happily repay you.

Fork seals and dust seals have been ordered. Picked up more oil today as well.

ben2go · July 25, 2007, 05:10:22 PM

Quote from: dgyver on July 25, 2007, 04:10:29 PM
Quote from: ben2go on July 23, 2007, 10:37:43 PM

ABSOLUTELY NO PROBLEM

I need seals and dust seals will you grab some for me also.95 Kat forks of course.I'll happily repay you.

Fork seals and dust seals have been ordered. Picked up more oil today as well.

Give me a ring on the telly so we can set up a day and time.Your camera is better then mine,but I can bring it.Doesn't have much compacity either.

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Rebuilding Kat forks