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how yo empty and refill forks.

Joined May 2010
10 Posts | 0+
cumming
who can please tell me how to drain and fill my front forks, its on a 1994 501 fc, any help would be great. thanks
 
Remove the fork legs, remove the caps, turn the fork legs upside down over a catch basin, and let the oil drain out. You need to pump them a bit to get all of it out. To refill, stand the legs right side up (putting them in a vise with a rag wraped around works great) with them fully compressed and pour in the fluid. The correct amount is determined by the level from the top and is done by over filling and then using a syringe to bring the fluid down to the pre-determined level. You can but fork oil level tools but I built one years ago using a section of brass tubing that goes through a piece of aluminum plate and held in place by a set screw (the amount of the brass tube that extends below the plate determines the oil level) with the large syringe connected to the brass tube extending above the plate.
 
Somehow I left one important step got left out of the above proceedure: the fork springs need to be removed and left out until you are ready to re-install the fork caps. To remove the springs you will need an open ended wrench to hold the cartridge (20mm?) and then you can unscrew the cap, allowing the spring to slide up and off. Also, before adjusting the oil level, (THE OIL LEVEL IS CHECKED/ADJUSTED WITH THE FORK LEG FULLY COMPRESSED) you need to slowly pump the fork leg up and down to work all the air out of the valve/cartridge assembly. The oil level should be 120-150mm below the top of the fork leg. The springs are are put back in as the last step before the caps are reinstalled but in order to do this you have to get a hold of the cartridge and pull it up as you extend the fork leg, quickly slide the spring on, and then get your open end wrench on the cartridge(over the top of the spring), then screw the fork cap back on the cartridge. This can be a bit messy until you get the hang of it!

It is a good idea to loosen the fork caps BEFORE taking the fork leg out of the triple clamp as it is easier to hold and the final tightening (just snug it it up good) of the cap can be done once the fork leg is reinstalled in the triple clamp. Also, DO NOT OVER-TIGHTEN the pinch bolts on the triple clamps as this can cause internal binding. The best proceedure is to tighten the pinch bolts in small increments, going back and forth between the 2 bolts on each clamp and using a torque wrench (your manual will have the correct torque values - for my '05 model they are 15-20Nm for the upper and 10-20Nm for the lower - yours shoud be about the same).
 

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