bent forks part deux

[Zachariah Mully]

KORG'ers- Well after finding out last Sunday that the KLR will stoppie if you use the rear end of a stationary Jeep, I finally got around this weekend to dismantling the front end of my bike. Previously I couldn't really tell what was bent, tweak or otherwise out of alignment, but as soon as I dropped the forks from my bike, it was as clear as night and day. I bent the right (from riders perspective) upper fork tube pretty several at the bottom triple clamp. The tube above and below that bend seem to be straight, hence my ability to limp it 2+ hours home with it bent. So I need some help getting this fixed and I turned to my local Kawi dealers. In general the upper fork tubes are ~$100 each (I figured I would replace both, even though the left seems pretty true, I can't imagine it escaped the impact untouched) and the labor and misc. parts are +$200!! After calling three shops in the area and getting the same answer from all, I whipped out my service manuals and decided to see exactly what was so difficult about installing the new fork tubes. From what I saw... Nothing that I don't think I couldn't do myself. But looks like it required at least three special Kawi tools (hence the cost?)... So... 1)Anyone replaced a bent fork tube themselves? How? Can I borrow your special tools or what did you use? 2)I bent the right, but like I said, the left looks fine, should I replace both regardless? 3)The shops said that new seals, dust covers and something else I can't remember needed to be replaced because of damage to the seals... The legs are straight from the triple clamp down and I rode it 2+ hours home with a through inspection before and after and detected no leaks in the front end. Are these parts just something you replace regardless as they wear out, or can I use my old ones? 4)I have heard of Franks Fork Service (or something like that), but I can't find them, anyone have a number for them or webpage? 5)Is this job too big/complicated/etc for me, so I should just get it to a dealer? ;-( Any suggestions, comments, or experiences would be most appreciated! I want to get back on the road for the fall season and I can't stand seeing my KLR disabled! Thanks, Zack 1991 KLR