So last ride out I managed to put a pretty decent gouge in my fork. Weird since i didn't even re-introduce the bike to the dirt like i usually do. I'm in the process of trying to repair with some epoxy, but may end up having to replace.

Question - Does any know if the lower fork tube on the 06/07's are different from other years? I know suspension travel shrank by an inch or so after 07 an that they have different part numbers from Kawi, but not sure that actually means they are different.

Anyone confirm this?

 

I'm not an expert on forks, but I would suspect that they are different. The 06/07 suspensions have more travel. I don't think epoxy is going to work.

If your not a fast rider, or don't do extreme dirt trails, you may be able just to get 2 tubes from another year and put them on as a pair, and ebay the other 07 that is still ok. But you loose 1-2" travel.

 

There's another thread currently running about possible services that recondition/repair fork tubes that might end up providing an option. Most people just replace, but new fork assemblies from Kaw are obviously going to be expensive. Finding a used leg or complete fork over the internet might be a solution.

I've wondered also about how different the fork components are between the '06/'07 models and later units. I'll bet the stationary upper fork legs are the same size. To get the lower suspension travel on the later models, it's all done internally, and whether or not they had to modify the length of the lower fork tube, that's the question.

I think the lower axle clamp method on later models is different too, is it not? That would change the part number and may require a different from hub or axle from the later model. I'm just spitballing on this. I just thought I remembers the front axle clamping design changing, but not sure.

 

There is a way they fix hydraulic tubes in industry, like back hoes and such. A guy I knew used to do it, no longer around so no help from him unfortunately. I think it's like an epoxy that fills the gouge that is applied then sanded, buffed, and polished round again, while on the machine. Don't know how it would work. You could do some research on it. You could also check with some hydraulic repair/rebuild shop to see if they could do the work. I used to work in a hydraulic repair shop that ground down and rechromed hydraulic tubes.

 

I have a set of forks from an '09 bike that had a bent frame. Shoot me a PM if you are interested. I will sell them cheap but the shipping from FL may be costly depending on where you are located.

 

price?

 

$40 plus whatever it costs to ship. I can send one fork or both, in the triple clamp or not.