1995 Revival

[Nails]

Go to "Installing Progressive Fork Springs" on https://amervoyassoc.org/techtipsXII.php (which is the Tech Tips page). (If I knew Gary Schill at all, I'd say something about the horse's mouth. But since I don't, I won't.)

I popped the fork caps while still in the triple-clamps. I found a way to leverage off the handlebars, using a 1/2" drive breaker bar (no socket) pushing right down on the plug. I could hold that with one hand, undoing the snap with the other. YMMV. So I didn't fuss with a vise at all. (To no avail -- the PO had already scratched the hell out of my fork tubes. But the seals still don't leak.)

I also went with 160mm oil because I had eliminated the entire "connecting pipe" and related plumbing. It works swell like that, but maybe more oil is better ... dunno. There's a good chance I wouldn't notice the difference.

I took my forks and parts to a shop for new bushings &etc, along with the referenced instructions. I got the forks assembled and ready to install. I have access to a good local shop.

[2wrems]

I went to the tech tips. It says the oil filter and collar don't go back in. It doesn't say don't put the spring spacer back in. That's why I asked.

I'll probably just take the fork tubes out to put the new springs in, I want to check the air cross connection pipe. I already have the new seals in.

[lucky13]

Hi . Just wondering where you were able to buy the high temp silicone hose for the fuel lines on your rebuild? Is it something readily available or? I saw Gene said he was able to get something at Motion Pro which we have here in Canada, but they have at least three different types/diameters.

[Nails]

I went to the tech tips. It says the oil filter and collar don't go back in. It doesn't say don't put the spring spacer back in. That's why I asked.

I don't know what you mean by a spring spacer, and I don't see it in the parts diagram. Some of us call the collar a spacer. Then there's bushings and a washer or two.

But it's been a while since I was in there; and I got that Can't Remember Shite disease.

[ekap1200]

Hi . Just wondering where you were able to buy the high temp silicone hose for the fuel lines on your rebuild? Is it something readily available or? I saw Gene said he was able to get something at Motion Pro which we have here in Canada, but they have at least three different types/diameters.

Hello, the fuel line that goes from the tank to the filter, when purchased from Kaw, is 2 different size's. Buy the 1/4 inch grey line it will fit nicely over the filter ( apx 5/16" ) . And you will be able to use the original hose clamps. It is the same OD, Which will give much better clearance at the bottom of the tank to the swing arm. It is not silicon hose but has been rated for todays fuel additives. The oem hose was not silicon , fits nice and it looks stock !
Gene Kap

[GrandpaDenny]

I went to the tech tips. It says the oil filter and collar don't go back in. It doesn't say don't put the spring spacer back in. That's why I asked.

I don't know what you mean by a spring spacer, and I don't see it in the parts diagram. Some of us call the collar a spacer. Then there's bushings and a washer or two.

But it's been a while since I was in there; and I got that Can't Remember Shite disease.

When Gene and I replaced Gertrude's front springs we followed the directions that came with the springs, with the exception of the recommended oil level (we used what was recommended here).

-Dennis

[2wrems]

Hi . Just wondering where you were able to buy the high temp silicone hose for the fuel lines on your rebuild? Is it something readily available or? I saw Gene said he was able to get something at Motion Pro which we have here in Canada, but they have at least three different types/diameters.

Hello, the fuel line that goes from the tank to the filter, when purchased from Kaw, is 2 different size's. Buy the 1/4 inch grey line it will fit nicely over the filter ( apx 5/16" ) . And you will be able to use the original hose clamps. It is the same OD, Which will give much better clearance at the bottom of the tank to the swing arm. It is not silicon hose but has been rated for todays fuel additives. The oem hose was not silicon , fits nice and it looks stock !
Gene Kap

From the sites i buy genuine kawi parts, it looks like the fuel line from the tank to the fuel filter is not available anymore. Looks like all the other ones are. I'm surprised there are so many parts still available for these bikes as it is.

[2wrems]

I went to the tech tips. It says the oil filter and collar don't go back in. It doesn't say don't put the spring spacer back in. That's why I asked.

I don't know what you mean by a spring spacer, and I don't see it in the parts diagram. Some of us call the collar a spacer. Then there's bushings and a washer or two.

But it's been a while since I was in there; and I got that Can't Remember Shite disease.

Well looking at the parts diagram, looks like the "collar" (part 92143-1053) is what i am calling the spring spacer. So what im seeing is the spring goes in, then nothing else except the top cap. The instructions from progressive call it a spring spacer, and all the other forks i have done call it a spacer. Hence my confusion.

[Nails]

Yeah, leave that out with the Progressives.

The service manual does have some funny names for things.

[2wrems]

Progressive springs installed. I think I fixed the air assembly too. The right side was all gummed up. Cleaned it out good and it's holding air. Took the fairings off again. Got new marker lights installed, adjusted the cruise module, and got the body all ready to go. She's ready to ride! Come on warm weather! I can see heated grips in the future. Have them on both my other bikes. Anxious to ride it now. I appreciate everyone's help.

[Nails]

The right side was all gummed up.

I noticed a fair amount of oil in my air manifold, including out the Schrader valve on the fairing. That's when I decided to plug the hole in the fork tubes.

I wonder what needed repair you'll find next.

[2wrems]

The right side was all gummed up.

I wonder what needed repair you'll find next.

haha, yea I'm sure something will come up. That's why I'm glad i took it for a spin around the block and saw the issue with the front suspension. The next day when its around 40 degrees and the roads aren't full of salt I'm definitely taking it out. Very satisfying to get this bike to where it is.

[2wrems]

Is adjusting the balancer gear backlash common? Something that needs done periodically?

[Barry]

Normally it's a set it & forget it operation. Easy job if you're looking for something to do.

[Barry]

Normally it's a set it & forget it operation. It's not something that needs done unless one of them slips out of adjustment. Easy job if you're looking for something to do.

[cushman eagle]

I have never found a reason to set the balancers on my'99. It has almost 92,000 miles on it ,bought it in November 2009 with 22,000 on it.

[Barry]

Is adjusting the balancer gear backlash common? Something that needs done periodically?

I found the comments on the tech page amusing:
https://www.amervoyassoc.org/techtipsXII.php#Engine
If your bike is in perfect tune, I mean carbs cleaned, adjusted & synced, new plugs and it still has an engine vibration, it might need the gear backlash adjusted. I've found most of the gear noise complaints are traced down to the rear end.

[2wrems]

So, I've been keeping an eye on eBay for good condition seats. Well i stumbled upon OEM replacement seat vinyl. Seems like the best/cheapest route. Assuming the foam is in half decent shape. I might buy some 1"-1.5" sheets of foam and i can use the spray adhesive to repair it. The current foam doesn't seem bad. The vinyl is the issue. Hopefully it turns out good. I've never done this before.
94-03 seats
https://www.ebay.com/itm/A622-KAWASAKI- ... 2230445240
86-93 seats
https://www.ebay.com/itm/KAWASAKI-ZG120 ... 4095635639

I did some google'ing on that company, seems like a good amount of people have bought from them and been happy. Even if they arent perfect, They will be 10x better than what is currently on it.

[SgtSlag]

There are videos on YouTube which demonstrate removing, and replacing, seat vinyl covers. Worth a look, as they are very good at showing how it is done. Never looked for anything specific to the Voyager, but I've looked at a few on the subject, in general. The principals are the same, no matter the make/model.

Never knew of any company offering new seat covers. Wonderful to hear of it! Cheers!

[Nails]

I didn't look at any ebay listings or vids, but I've successfully re-covered several m/c seats both using bought covers and making my own. Reupholstering with bought covers is easy, using spray upholstery adhesive (this usually is unnecessary) and a staple gun into stock plastic seat pans. See vids about how to start, and then just stretch and staple. (If you ride a dirt bike as intended, you'll have done this dozens of times. )

Rolling your own upholstery is a little more difficult; and I'd hesitate to approach it without an industrial sewing machine. The best material you can find generally is worth the money. I've successfully replaced panels in my XII pillion upholstery (the top pieces that rotted in the sun); and then dumped it all with later mods fabricating a new butt rest and back rest. It's definitely doable at home.

On the other hand, I've reupholstered car seats, carefully using the fried covers as a pattern, and it turned out awful. YMMV

I might buy some 1"-1.5" sheets of foam

I don't think that'll work very well. The foam needs to be sculpted. That's more difficult than it might seem. If the foam is shaped right but has gone soft, consider cutting out a piece of 1/2" ensolite pad to put under all the foam.