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· Moderating: Fair & Just
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Discussion Starter · #1 · (Edited)
Special note:
I will be describing this using OEM specs. With any forks that have been modified or are planning to be modified (in an acceptable manner), adjust procedures accordingly.



Remove the main fairing.
Seat, Tank, Fairing removal
Remove the front wheel.
Front Wheel R&R
Remove the fender.


Remove this piece of plastic held by the one phillips screw. (One on each side of the bike)



Loosen the upper triple tree clamp bolt.



Loosen the lower triple tree clamp bolt. Drop the fork down until the top of it is just above the lower clamp. Retighten the lower clamp bolt. As long as it's snug enough to hold the fork will be fine, won't need to be torqued to spec here.
Tip: It won't be necessary to remove any of the zip ties on the forks. The forks can easily slip out and back into those.



Take a gear puller.



Place it with the bolt of the puller on top of the fork and the legs of the puller grabbing underneath the triple tree. Screw the puller bolt down as to depress the fork cap low enough to remove the cap retaining ring. Remove the cap retaining ring. Loosen the puller bolt to release it off the bike. Hold on to the fork parts that will come off while doing this. Loosen the lower triple clamp bolt and remove the fork. Remove the main spring and turn the fork upside-down to drain the oil. Pump the inner and outer fork like a bicycle air pump to get the majority of the oil out.



Top end fork parts:
A. Long spring
B. Washer
C. Spacer
D. Fork cap
E. Fork cap retaining ring

Note:
The OEM spring length when new is 434.5mm. With a service limit of 425mm.
The fork cap has an O-ring that should be replaced.
It's best to leave the forks upside-down for a while to drain maximum oil.


If you're going to be replacing the fork seals, stop at this point.
Refer to this thread>Replacing Fork Seals
If you're just changing the oil, continue on.



Turn the fork right-side up and replenish the oil. Specs call for the oil to be at a level 117mm below the top of the fork (+ or - 2mm), with the fork fully compressed.



I have fashioned a makeshift dip stick for this. ;)
After replenishing at least the majority of the oil, you will want to pump the inner fork tube several times to get the oil into the bottom of the fork.


Once the fork oil level is correct, place the long spring into the fork top smaller diameter first. You will want to extend the fork a bit to keep from losing any oil while doing this. Place the fork back into the triple tree to where the top of it is just above the lower clamp and snug the clamp up a bit. Place the washer with the concave side (or flatter side) of the washer on the spring. Then the spacer and finally the fork cap. You will need to be pressing these parts in most of the way by hand. Then take the gear puller and place it on the fork as done during the removal. With the puller depress the cap far enough to reveal the groove that holds the retaining ring. Install the retaining ring. Remove the puller. Loosen the lower triple clamp bolt. Push the fork into the upper triple while feeding it through the zip ties (if you left the zip ties in place). Torque down the lower clamp to 25ft.lbs. Then torque down the upper clamp to 14.5 ft.lbs.

Reinstall all other parts and we're done.
 
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