Fork Disassembly Experts...PLEASE

[Steve K (IA)]

Can you get all the oil out by standing the lower fork legs upside down without a complete tear down of the inner works?
 

[Dag]

Yes you can.
Remove the fork leg (have a bucket ready to catch some oil when you pull it out) and turn it upside down.

http://www.valkyrienorway.com/forksprings.html

[woefman]

Yes you can.
Remove the fork leg (have a bucket ready to catch some oil when you pull it out) and turn it upside down.

http://www.valkyrienorway.com/forksprings.html

Hey Dag , Great link.

Curious why you left the Upper Forks on the Bike ?  I only Helped do one Valk set of fork seals, but I have another set to do. ( HDL parts let us down) I was going to do my Buddies Valk, before Inzane
but all parts arrived but the seals. He had to ride a Yamaha to Inzane 9  grrrrr.

Speaking of which I think that will make 2 more valk guys going to inzane that are not on this board.

My buddy Rick and His Friend.

I also have another Buddy That is unsure of going. SO maybe three more total to represent AZ.

[Dag]

Yes you can.
Remove the fork leg (have a bucket ready to catch some oil when you pull it out) and turn it upside down.

http://www.valkyrienorway.com/forksprings.html

Hey Dag , Great link.

Curious why you left the Upper Forks on the Bike ? 

Less work...  (I think  ) I have always done it this way

[woefman]

Yes you can.
Remove the fork leg (have a bucket ready to catch some oil when you pull it out) and turn it upside down.

http://www.valkyrienorway.com/forksprings.html

Hey Dag , Great link.

Curious why you left the Upper Forks on the Bike ? 

Less work...  (I think  ) I have always done it this way

Thank You

[Steve K (IA)]

The reason I posted the question...a few weeks back I changed the seals and bushings on my 2000 I/S.  I asked the same question then about getting all the oil out and didn't get a response, so I continued on with the job assuming that all the oil would come out if I left them standing upside down overnight.  I added the correct amount of oil.  I did not do the measure method because if all the oil came out, it should be right.  Well, they leaked a little bit right away.  I just returned from a 1500 mile trip and the front of the bike is completely covered in oil.  I could look down at the forks as I was running down the road and see the big drops of oil hanging off the dust seal.  Apparently, I overfilled them considerably.  Meaning all the oil didn't come out.  Now I have to tear it all down again and figure out a way to suck out the excess. 

I see where Progressive Suspension has a devise just for this, but they want about $38 for it. 

Any other ideas?

[Gryphon Rider]

When I did my fork seals I didn't fully disassemble the forks, but left the springs in.  I did drain them thoroughly (I think), fully extending them, pumping them, leaving them to drain overnight, etc.  When installing the new seals I covered the end of the inner fork tube with masking tape per the service manual instructions to prevent damaging the seals.  I added the proper amount of new fork oil using a 250 mL graduated cylinder, allowing plenty of time for the last few drops to drain from the cylinder each time.  I have ridden my bike a few months now and the forks haven't leaked at all.

How did you measure the new fork oil, Steve K?

[9Ball]

The reason I posted the question...a few weeks back I changed the seals and bushings on my 2000 I/S.  I asked the same question then about getting all the oil out and didn't get a response, so I continued on with the job assuming that all the oil would come out if I left them standing upside down overnight.  I added the correct amount of oil.  I did not do the measure method because if all the oil came out, it should be right.  Well, they leaked a little bit right away.  I just returned from a 1500 mile trip and the front of the bike is completely covered in oil.  I could look down at the forks as I was running down the road and see the big drops of oil hanging off the dust seal.  Apparently, I overfilled them considerably.  Meaning all the oil didn't come out.  Now I have to tear it all down again and figure out a way to suck out the excess.  

I see where Progressive Suspension has a devise just for this, but they want about $38 for it.

are you sure you put the seals in the right way?  They're inverted forks....Many have made this mistake.

Any other ideas?

[Dag]

The reason I posted the question...a few weeks back I changed the seals and bushings on my 2000 I/S.  I asked the same question then about getting all the oil out and didn't get a response, so I continued on with the job assuming that all the oil would come out if I left them standing upside down overnight.  I added the correct amount of oil.  I did not do the measure method because if all the oil came out, it should be right.  Well, they leaked a little bit right away.  I just returned from a 1500 mile trip and the front of the bike is completely covered in oil.  I could look down at the forks as I was running down the road and see the big drops of oil hanging off the dust seal.  Apparently, I overfilled them considerably.  Meaning all the oil didn't come out.  Now I have to tear it all down again and figure out a way to suck out the excess. 

I see where Progressive Suspension has a devise just for this, but they want about $38 for it. 

Any other ideas?

You do get all the oil out by turning them upside down.
It should not leak even if its overfilled.

[Steve K (IA)]

When I did my fork seals I didn't fully disassemble the forks, but left the springs in.  I did drain them thoroughly (I think), fully extending them, pumping them, leaving them to drain overnight, etc.  When installing the new seals I covered the end of the inner fork tube with masking tape per the service manual instructions to prevent damaging the seals.  I added the proper amount of new fork oil using a 250 mL graduated cylinder, allowing plenty of time for the last few drops to drain from the cylinder each time.  I have ridden my bike a few months now and the forks haven't leaked at all.

How did you measure the new fork oil, Steve K?

I wrapped electrical tape around the top of the tube and around the groove that the slider bushing sets in to keep from damaging the seals when slipping them on the tube.

The seals only go in one way.  I am a machinist/ toolmaker by trade so the seals have been installed and seated properly.

I used a measuring cup to measure the oil.  The manual say's 24.8 US oz.  That sure seems like a lot of oil, but that is what I put in.

Guess I don't know what you mean by pumping the forks and why? 

[Steve K (IA)]

Well, I guess I need to buy 2 new seal sets and tear everything apart and do it over.  I sure don't know what went wrong.  The oil seals have a taper on one end, that should be the end that is pressed into the tube...or maybe not.  The closer I look at the picture in the book, it looks like the end of the oil seal with the chamfer is facing downwards.  I'm certain I installed the new seal the same way the old seals came off.  There is only one way to find out....

[Gryphon Rider]

I can't remember if the pumping made a difference for draining the old oil, but it seemed that every time I fully compressed an extended the forks (on my workbench) a little more came out.  I went to the trouble of buying a graduated cyclinder because the manual specified a volume of oil ±2.5 cubic centimetres (a.k.a. millilitres) (±0.08 US oz).  There is no possible way to get anywhere near that accurate with a kitchen measuring cup.

BTW, my manual says 22.7 oz right, 25.2 oz left for Standard or Tourer, and 22.6 oz right, 24.8 oz left for Interstate.

[Bugslayer]

  My left side seal is leaking as we speak. But I can't for the life of me understand how the fork seals, bushings and other parts go together. I've had the forks off the bike to replace the springs, but I've never had the fork's taken apart.  I've taken care of all  the maintenance and other problem's that have come up. But for some reason, taking the forks apart intimidates the hell outta me.

Anyone in the Lubbock, Tx area willing to help will be rewarded with a dinner of their choice.   

[Steve K (IA)]

I can't remember if the pumping made a difference for draining the old oil, but it seemed that every time I fully compressed an extended the forks (on my workbench) a little more came out.  I went to the trouble of buying a graduated cyclinder because the manual specified a volume of oil ±2.5 cubic centimetres (a.k.a. millilitres) (±0.08 US oz).  There is no possible way to get anywhere near that accurate with a kitchen measuring cup.

BTW, my manual says 22.7 oz right, 25.2 oz left for Standard or Tourer, and 22.6 oz right, 24.8 oz left for Interstate.

OK, I found those measurements in the front of the book.  In the back of the book in the details of changing the fork seals, it only mentions the 24.8 oz with no reference to right or left.  They must of split the difference. 

[Steve K (IA)]

  My left side seal is leaking as we speak. But I can't for the life of me understand how the fork seals, bushings and other parts go together. I've had the forks off the bike to replace the springs, but I've never had the fork's taken apart.  I've taken care of all  the maintenance and other problem's that have come up. But for some reason, taking the forks apart intimidates the hell outta me.

Anyone in the Lubbock, Tx area willing to help will be rewarded with a dinner of their choice.   

I was the same way...intimidated.  The right side started leaking last year, got the seal sets and put it off until a few weeks ago.  It isn't hard at all, but apparently, I put the oil seals in upside down .  So in the morning I will call and see if the dealer has them in stock, they did last time.  At least this next time around, I bet I don't spill one drop of oil. 

[Bugslayer]

I was the same way...intimidated.  The right side started leaking last year, got the seal sets and put it off until a few weeks ago.  It isn't hard at all, but apparently, I put the oil seals in upside down .  So in the morning I will call and see if the dealer has them in stock, they did last time.  At least this next time around, I bet I don't spill one drop of oil. 
[/quote]


 I've even put off ordering the parts cause I'm not sure what I need. I've looked at the shop manual and Dags website, but it's still all Greek to me... LOL.

OK... I'm talking ALL YOU CAN EAT RIBS W/ ALL THE FIXIN'S... or a STEAK DINNER WITH A BAKED POTATO SWIMMING IN BUTTER AND SOUR CREAM... Surely that's worth a road trip to Lubbock...   

[Steve K (IA)]

if you are just replacing the seals, you should also replace the bushings also.  Here are the part #'s and quantity of each that you will need.

SEAL SET, FR. FORK...need 2 of these                  $19.92 ea.
51490-MW0-003
(In each of these sets are 1 oil seal and 1 dust seal)

BUSH, GUIDE....need 2
51414-MT7-003                                                  $13.09 ea.

BUSH, SLIDER....need 2                                        $6.15  ea.
51415-MCH-003

These are HDL prices
 

[Bugslayer]

if you are just replacing the seals, you should also replace the bushings also.  Here are the part #'s and quantity of each that you will need.

SEAL SET, FR. FORK...need 2 of these                  $19.92 ea.
51490-MW0-003
(In each of these sets are 1 oil seal and 1 dust seal)

BUSH, GUIDE....need 2
51414-MT7-003                                                  $13.09 ea.

BUSH, SLIDER....need 2                                        $6.15  ea.
51415-MCH-003

These are HDL prices
 

Excellent! Thanks.  

[RP#62]

After having done several of these over the years, I've come to the conclusion that the volume quoted tells you how much oil to buy and the linear dimension from the top of the tube, tells you how much to put in.  How much you have to add is going to vary depending on whether you are starting from a clean dry assembly, or from one thats been minimally disassembled and still contains has residual oil.  The tube has a relatively small inside diameter and it doesn't take much of a volume change to make a significant difference in the linear dimension from the top of the tube.
My 2 cents.
-RP

[Ricky-D]

I'm thinking that the left side shock will drain all the oil if turned top down.

I think the right side will not give up all the oil due to the presence of the damper inside the tube.

The damper is a closed circuit with a valve to attenuate the rebound of the shock. it will want to hold the oil.

***

[humshark]

I'm with Steve K -

Anyone in the Nashville area want to wrench with me on my forks?  I need to see it once with the help of experience and then I'll be fine.  Mine started leaking again after a really good "jump". ( small ditch - long story )

I'm running progressive springs and I have heard that they recommend less amounts of oil.... Is this correct?

[Larry]

Hope you had a happy landing! Other than the fork seal issue. 

[humshark]

Hope you had a happy landing! Other than the fork seal issue.

Everything went as good as it could have, all things considered.  I lost my pride in the deal was all.  I think I left him (pride) laying in the grass on the far side of the ditch.  ( this happened a couple of months ago now )

Right fork leaks some now, so does the left, but not as much.  I keep them cleaned and know that I have to replace the seals soon.  AGAIN - Anyone in the Nashville TN area want to wrench a bit?  I'll treat!  I'll order the parts to have on hand.

[Steve K (IA)]

Well, the local dealer had 2 seal sets.  Talked to a mechanic while I was there and he confirmed that I put the seals in upside down....because I do remember how I put them in.  Guess I ain't as smart as I thought I was.