Bicycle Repairman

So the next day I rode it to our local moto enthusiast hang out here in Tucson, Gear Shifters, and the owner immediately invited me to submit it for curation in the 520 Moto Show presented by Iron Horse Motorcycles (shameless plug). I didn't have to think about that too long. It now has a little over 200 miles on it! I think the fueling is not quite right though. The pilot jets are for Portland elevation around 400 ft. give or take and i'm now at over 2200 ft. Or maybe the fuel pump is gunky or maybe the fuel filter is gunky. In any case, I still have some fueling issues to work out. Other than that, I feel a rock star riding it! I finally found a downloadable service manual that covers the 1995 with the KYB USD fork and figured out how to free the spring from the damper rod. Of course it requires a special tool that can easily be improvised with some plastic pipe and a washer but since the seals can easily be replaced without disturbing the spring, I decided to simply wash everything with Maxxis Suspension cleaner and call it good. Rather than using air space to measure oil, I used volume. I put in slightly more than 16 US ounces in an effort to stiffen the compression a bit. I also used 15W oil. I won't bore you with all the work, time and money I put into this project but it was a fight at every turn. Now the bike that had been "stored" for 29 years with 162 miles on the odometer, now has 168 miles on it. Tomorrow, much more! https://www.facebook.com/bicycle.repairman.75/

I finally found a downloadable service manual that covers the 1995 with the KYB USD fork and figured out how to free the spring from the damper rod. Of course it requires a special tool that can easily be improvised with some plastic pipe and a washer but since the seals can easily be replaced without disturbing the spring, I decided to simply wash everything with Maxxis Suspension cleaner and call it good. Rather than using air space to measure oil, I used volume. I put in slightly more than 16 US ounces in an effort to stiffen the compression a bit. I also used 15W oil. I won't bore you with all the work, time and money I put into this project but it was a fight at every turn. Now the bike that had been "stored" for 29 years with 162 miles on the odometer, now has 168 miles on it. Tomorrow, much more! https://www.facebook.com/bicycle.repairman.75/

If I'm interpreting correctly, the level is measure with springs out, stanchion collapsed and adjuster full out. (0 mm preload)

I believe 1995 was the last year. Thank you, Neo! That's exactly what I needed. I'm not sure what "Preload Adjuster 0 mm Range" means though. My forks have adjustable preload.

Thanks for trying. The '87 fork is completely different. '95 was the first year the KYB USD (upside down) for was used. I have a manual for earlier models but not the '95 supplement. Hours of scouring the interwebs has turned up nothing.

My first Yamaha was a 1980 XS850 Midnight Special the previous owner had installed lower bars and a bullet fairing. I wish I still had that one. The current project is a 1995 FZR1000 EXUP with 162 miles on it. It was "stored" (neglected) for 28 years. During the year it sat (neglected) in my garage, mice had filled it with dog food and damaged some of the wires. Long story short, the last thing before it's like a new bike is fork seals but I don't have 1995 manual/supplement to tell me the factory air space/oil lever for the KYB USD forks. I assume compressed with springs out. Anyone? Thanks, Danny