KLX300 fork oil

7 replies to this topic
  • DaveE

Posted December 20, 2004 - 08:08 PM


I have a very slight leak in one fork, read the service manual, which states that you need to take the forks out of the tripple clamp and use a bunch of special tools to check or change the oil. Does anyone know an easier way than taking the forks off the bike to add or change the oil?


  • coopou812

Posted December 20, 2004 - 09:26 PM


The owners manual says to do the following if you don't want to remove the forks:
*raise the front wheel
*remove the fender, meter cable & unit, headlight, handle bar, fork protectors
*loosen the fork upper clamp bolts
*remove the caps from the top of the fork tube
*fully compress the fork tube so the dust cover touches the bottom and place a stand to hold it
*remove the springs
*set the oil level 68mm (standard) or 60 - 90 mm (adjustable) from the top of the tube

It may be easier to remove the tubes and you could replace the leaky seal at the same time. I did this recently and put in new springs too. It was my first time working on forks. With help from TT members and the service manual it was fairly easy. I didn't buy an oil gauge, seal driver, or spring holder. I used a ruler to measure the oil and a medicine dropper to remove any excess. For a seal driver I used a piece of PVC pipe cut in half then secured around the lower tube to drive the seal. Try a search on replacing fork seals for more info. Good luck.

  • KLeeneX300

Posted December 20, 2004 - 09:31 PM


Changing your fork seals/oil is pretty easy. Only simple tools are needed. 10mm and 17mm wrenches and a 30mm to remove the fork caps. The only other tool you need is a fork seal driver. You can buy one(spendy) or make your own out of PVC pipe(cheap) If this is your first time I would also get a new roll of paper towels.


  • Bill_P

Posted December 20, 2004 - 10:06 PM


To add oil you can do as was said before, but if it's gunky and you want to change it out, you'll need to remove the forks. There's no drain in the bottom. The oil has to come out the top. Of course you could always jerry rig some sort of ball and tackle contraption to raise your bike off the ground - upside down - and drain it that way..... :cry: :cry: :cry: :cry:

Seriously though, it's really easy. Have you tried the film negative / small feeler guage trick on the dust seals to clean them out? The KLX seals seem to be real good. Just when I think I've got a bad seal, I do the film negative trick and they seem to be good for another 6-8 months.

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  • coopou812

Posted December 21, 2004 - 02:33 PM


The oil has to come out the top. Of course you could always jerry rig some sort of ball and tackle contraption to raise your bike off the ground - upside down - and drain it that way..... :cry: :cry: :cry: :cry:

:cry: That's funny. I'd like to see a picture

  • DaveE

Posted December 21, 2004 - 07:53 PM


Guys, thanks for the tips, I tried the negitive trick and am going to watch it to see if it works.

I have to say I am really glad there are a great bunch of guys on this forum that are willing to share advise and knowledge, so far there has not been an issue that I could not get help with!

Guys have a great holiday, Thanks

  • Cowtipper

Posted April 04, 2005 - 06:24 PM


Just joined after seeing you message about cleaning the fork seals with a film negative. You saved me some cash.

Thanks!!!!!!!!! :naughty:

  • Bill_P

Posted April 04, 2005 - 09:39 PM


Cowtipper, glad to help out & welcome. You'll find a lot of good info for the KLX and other bikes around here. Cheers, Bill

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