Here's how I installed the repair kit.
I just replaced the joystick swivel components last week at 155 hrs on a 2003 KL120. It was a p.i.t.a.
The shop service manual is worthless for this procedure and the parts kit doesn't have any instructions with it. KIOTI ARE YOU LISTENING?
You have to diassemble the whole joystick from the fender down to the cable connections at the valve block. You cannot unbolt the swivel ball from the cable at the joy stick end. It must be done from the valve end. Then you can retract the cable enough to access the ball lock nuts to undo them.
Besure to note how much thread is showing on the large cable lock nuts on BOTH ENDS. You will need to get the thread close to these measurements as possible to make proper adjustment easier. The final adjustment has to be done at the valve block end by screwing the outer cover (the grey metal diecast outer cover)(also besure that the orings are in their proper place in the cover to seal against the valve body) in or out then locking the large cable locknut.
I found the best way to adjust the swivel and cable was to turn the cover in or out until the joystick locking lever slips into place easily.
I feel the nylon ball cover over the swivel balls is either a poor design or a bad batch of plastic. Since this problem appears to occur on machines from several model years ,one would assume that it is a poor design issue.
Also the cost of the kit is a little steep at about $75.00 , and if you're out of warranty and have to pay for labor it will take an hour or two depending on if the tech has done this before.
Good Luck.
I just replaced the joystick swivel components last week at 155 hrs on a 2003 KL120. It was a p.i.t.a.
The shop service manual is worthless for this procedure and the parts kit doesn't have any instructions with it. KIOTI ARE YOU LISTENING?
You have to diassemble the whole joystick from the fender down to the cable connections at the valve block. You cannot unbolt the swivel ball from the cable at the joy stick end. It must be done from the valve end. Then you can retract the cable enough to access the ball lock nuts to undo them.
Besure to note how much thread is showing on the large cable lock nuts on BOTH ENDS. You will need to get the thread close to these measurements as possible to make proper adjustment easier. The final adjustment has to be done at the valve block end by screwing the outer cover (the grey metal diecast outer cover)(also besure that the orings are in their proper place in the cover to seal against the valve body) in or out then locking the large cable locknut.
I found the best way to adjust the swivel and cable was to turn the cover in or out until the joystick locking lever slips into place easily.
I feel the nylon ball cover over the swivel balls is either a poor design or a bad batch of plastic. Since this problem appears to occur on machines from several model years ,one would assume that it is a poor design issue.
Also the cost of the kit is a little steep at about $75.00 , and if you're out of warranty and have to pay for labor it will take an hour or two depending on if the tech has done this before.
Good Luck.
