How To: KYB Fork Rebuild (Part 1)

Part one with TBT Racing's Travis Flateau as he rebuilds a KYB fork.

[@4touchdowns1game29]

A documentary needs to be made about kayaba sss forks. Crazy how long they have been around and they are still the best you can get on a stock bike.

[@twowheelpilot]

Agreed 👍 better than shit house WP forks! 4CS, hahahahaha now changed into explore which is a 4cs re-hash as WP had heaps to get through! Twin Chamber was the last good WP mass produced fork.

[@TheDirtyBirchTrails]

Still relevant today. Just got my latest weapon, a 2024 Stark Varg. Same forks !!

[@jdoggriffo3171]

Travis I haven't even looked at my owners Manuel yet because your advice has been very helpful, thank you

[@cbh148]

Very helpful video. I've got a '05 YZ125 (crappy KYB AOSS forks) so I got on ebay and bought some '09 YZ250F SSS forks. Just showed up yesterday so I started the rebuild, and unfortunately for me, the free piston is already busted on one of the legs. Was going to drill them out to prevent it, but oh well. Ordered some Zeta aluminum free pistons.

[@derekalexander5691]

Absolutely well done. A little more detail would be great but that’s your business. Appreciate with what info you have provided.

[@mikeking7388]

A pro at work! Can’t wait to dig into mine

[@BraapMedia]

Good instruction! My -06 YZ125 had a bad oil seal on the right side of the fork so now the replacing will be easy! I was a bit confused at first because I've never done this myself. So tomorrow I'll go and buy a new seal and start working.

[@genreaper]

Watched your video and was very helpfull in helping me service my forks. Thanks alot great job.

[@cisterna102]

Hi everyone. I watched this video and I have a question for it. Since I don't understand much English, I need advice on why it's drilling holes in the valve(6:40min) and where will the hole be down or up?

[@christhegreatfirst]

Excellent video Travis. I will be calling to purchase the DIY kit from you

[@TrevorAvrett]

So efficient! Thanks man

[@anthonycavalliotis8736]

Great video. What size is the inner cap tool. 32mm or 36mm thanks.

[@vincentsauer99]

What size has the internal cap wrench?

[@marko6394]

Doesn't pushing the rod out cause damage to the rod seal thus requiring replacement?

[@kostasrestas]

hello my friend! i have an xt660z tenere 2008 and some days before i replace the forks and the wheel with forks and wheel from wr426f now i have to change the springs with stiffer ones because tenere is way more heavy and i'm 100 kilos. but i don't know what springs i buy.. what i have to check ,calculate or consider before i buy???

[@KalajengKING508]

thx for a very informative video, just bought myself a second hand 05 YZ250f fork, oil on the outer chamber was less than 200 cc, I had to try to lower the for by 1 inch, put a 1 inch bushing in the inner chamber shaft and replaced the lower plastic spring guide with a shorter PVC pipe...going for 2 inch lowering next time. also..is carb cleaner okay for cleaning? your oil and cleaners are hard and expensive to come by here in Jakarta.

[@ericstyer2890]

Got any vid showing 03ish Yz250f rebuild? I’ve found a blue bumper that’s come apart as well as what appears to have been a round wire spacer maybe that came off near the stack for base valve.

[@ress87]

Nice work! What vice is that?

[@apollomorris9920]

How must dose a revalve spring polishing cost ? And a good rear shock on an Aprilla rsv4

[@onthetrail894]

Will the hole drilled into the free piston effect the damping?

[@Blypanna]

Damn, you are fast! Impressive video, tnx for sharing!

[@bittechslow]

Hi Travis,exellent video. I just bought a yz450f with 40 hrs on it ,it had a bad fork seal so im doing the bushes and seals.This video was brilliant ,best yet.I got a question for you if you got the time. My yz is a 2011 ,do you think i should do the hole in the piston? Is this a design oversight on the KYB? I guess thats 2 questions . You have been a big help to an old dirt rider.

[@AREA-51moto]

Thank you

[@andrewk157]

At 2:40 in the video you seem to be able to screw off the little aluminium nut off of the shaft. Mine appears to be seized on there. Have you had this problem, or d o you have any suggestions to get it off? I'm thinking of buying two nuts and locking them together on the end of the shaft to hold the shaft from moving.

[@jerrylc4631]

Hey did you succeed? I have the same issue..

[@andrewk157]

Jerry LC I think I just used brute force. It was five years ago.

[@jerrylc4631]

I'm doing that too, and add wd40 then wait, then do it again.. hopefully it'll be loose tomorrow morning

[@dirtbikeevent7162]

Hey Al Quida, get some Honda forks and wear out the seals. They will explode.....

[@emanulian]

I`m like "bittechslow"... Whay do you drill the piston?!

[@Oxigan2win]

where can I buy this "do it yourself front suspension rebuild kit"?... Would be awesome if there is some vendor in europe who sells this.

[@igortbp]

Good afternoon, this is the same procedure for the suspension of YZ250F 2008? Thanks!

[@fox7007]

+Igor Vinicius yes

[@Chris-uh3cm]

Not sure but, i heard supposed to back out "cliockers" before doing this?

[@100GTAGUY]

I'd consult your service manual on that step, most bikes should have some technical info direct from KYB for the suspension inserted in their manuals.

[@avilarr]

Great Video thanks for the help!

[@mgebs311]

How fine is that file?

[@b.c.h4120]

Wear your gloves when using cleaners/solvents. Hexane in that cleaner is bad stuff. Had a friend develop blood cancer and die because he never wore gloves as a mechanic.

[@AdrenalineRushMX]

i dont care about spliting my case but fork work i cant lol

[@jayrapp605]

Don't drill the hole.

[@tedpaszko8274]

The hole released presure to keep the plastic part from breaking

[@A-mechanics-review-4U]

Ted Paszko So you mean to tell me that this KYB company just didn’t know to do this and that these are the best forks that are still trying to be beaten since 2007 to this day and you’re telling me they didn’t know the drill the hole come on man

[@bpb7338]

@@A-mechanics-review-4U You are very narrow focused person, that's why everything in your life coost more....check per example SDI Elite Fork free Piston... In the age of information, ignorance is a choice...🤣🤣🤣🤣🤣 KYB sucking money from ignorant people all the time...

[@RizwanRizwan-pq8wx]

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