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Thread: How to Replace Motorcycle Fork Oil [Fork Reconditioning]

  1. #1
    Rusted paul.1911's Avatar
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    Default How to Replace Motorcycle Fork Oil [Fork Reconditioning]

    Changing motorcycle fork oil is a part of regular maintenance on a bike and can easily be done in-home shop or garage. Make sure everything is kept clean and pay attention to what your owner's manual recommends for oil versus air height. Change the oil in your motorcycle forks every year to insure long life and proper function of the bike.

    REMOVING

    Remove front wheel, mudguard, and temporarily install fork in a pinch bolt to loosen the top cap. Just loose it.

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    Then remove the fork cap.

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    Push the pipe down and remove spring collar.

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    Remove joint spring washer.

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    Remove fork spring.

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    Drain the oil by pumping the pipe several times.

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    To separate pipe from base, loosen this hex bolt this way using adjustable spanner, it will be easier to loose. And use any pipe or just any ring spanner to apply the torque easily.

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    When you have loosen the bolt, the piston inside will rotate freely. Then insert piston removal tool to hold the piston inside. Remove the bolt and pull the pipe out.

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    Remove the piston out and remove the rebound spring.

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    Remove oil seal lock.

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    And remove oil-seal this way using cloth, that will prevent the base from being damage. Also don't damage the oil-seal seat while removing oil seal.

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    INSPECTION

    Inspect piston, pipes, base for any score marks, scratches or abnormal wear. Check piston ring for any fatigue or damage. Replace any components that are worn or damage.

    Place the pipe in a V blocks, or flat surface (I prefer glass) and check if it is bent or straight. If found bent then get it straight on a lathe or simply buy a new one.
    It should not be more than 0.20 MM run out.

    Before assembly, wash all parts with a high flash/non-flammable solvent (kerosene) and wipe them dry.


    INSTALLATION

    Apply new fork oil around oil seal lips and install it in a base with its marking facing up or two rings facing downwards. Use old oil seal to drive it inside or simply use oil seal driver tool if you have after installing pipe. Then install oil lock.

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    Insert piston inside fork pipe and insert oil lock piece. And drive it inside the base. Before inserting apply fork oil to the oil seal to prevent dry sliding.

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    Replace both O-ring and washer before installation. You can also apply gasket sealant to the copper washer to ensure better sealing.

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    Then insert piston remover tool and tighten the piston socket bolt.
    TORQUE: 20 N�m (2.0 kgf�m, 15 lbf�ft)

    Install dust seal. When you will be sliding dust seal from up to down it will carry dust with it. Then pull it up and clean the dust. Repeat this several times and then install it. This will ensure you there is no dust below the dust seal cap.

    After fitting, push the pipe all the way down and pour exactly 160 ml of new fork fluid.
    (Check your owners manual before pouring, it is different for different manufacturers)


    Pull the fork pipe up and insert fork spring with its tapered (narrow coil pitch) facing downward.

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    Then pump the fork pipe 10~15 times up and down to remove trapped air from the lower portion of the fork pipe.

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    Install washer, collar. Apply fork oil to the new cap o-ring and install the fork cap on to the fork pipe. Press and rotate until it catches the thread.

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    Then temporarily install fork on your bike pinch bolt and tighten it.
    TORQUE: 22 N�m (2.2 kgf�m, 16 lbf�ft)


    Rotate your fork opposite so that fluid touches the collar. That will prevent your collar from being rusted.

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    Then install it on your bike. And drive on to test it
    Last edited by paul.1911; 07-05-2017 at 01:51 AM.
    Everyone crashes. Some too scared to get back on. Some can't wait to ride again!

    DIY - Foam Air filter Cleaning & Oiling / Horn Repair Guide / Replacing Motorcycle Fork Oil

    Read This Before You Buy Any Halogen Bulb
    Engine Overhaul

  2. #2
    Moderator The Monk's Avatar
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    Default Re: How to Replace Motorcycle Fork Oil [Fork Reconditioning]

    DIY Approved

    Another good one bro. Thanks
    Biking is not about what you have between your legs, its all about how well you use it!!!!!!!

    Give your details here if you want to help your fellow xBhpian stranded in your city

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    Default Re: How to Replace Motorcycle Fork Oil [Fork Reconditioning]

    Where do I get the piston removal tool and the seal driver? I guess a pieces of PVC will work to drive the seal.
    srikany likes this.

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    Rusted paul.1911's Avatar
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    Default Re: How to Replace Motorcycle Fork Oil [Fork Reconditioning]

    Quote Originally Posted by Cleaner View Post
    Where do I get the piston removal tool and the seal driver? I guess a pieces of PVC will work to drive the seal.
    I have made piston removal tool myself in a grinding wheel. You can try finding in a tools shops who also keep special tools for bikes. Or else if you have access to grinding machine or have few old rods in your home, you can get it grind in a lathe. You would need 13 mm rod and 22~23 inches long would be enough. Or you can also take it from your mechanic you know better. Take it when its his off day so that he will not ask you to give it back urgently and you will have enough time for your DIY.

    As I have mentioned, you don't need seal driver if you don't have. Use old oil seal to drive in the new seal. Then fit the lock, pipes and all.
    srikany likes this.
    Everyone crashes. Some too scared to get back on. Some can't wait to ride again!

    DIY - Foam Air filter Cleaning & Oiling / Horn Repair Guide / Replacing Motorcycle Fork Oil

    Read This Before You Buy Any Halogen Bulb
    Engine Overhaul

  5. #5
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    Default Re: How to Replace Motorcycle Fork Oil [Fork Reconditioning]

    Could you post detailed instruction on how to build the rod? There is not a single mechanic that I'm in good terms with and no tool shop who stocks special tools.

  6. #6
    Rusted paul.1911's Avatar
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    Default Re: How to Replace Motorcycle Fork Oil [Fork Reconditioning]

    Quote Originally Posted by Cleaner View Post
    Could you post detailed instruction on how to build the rod? There is not a single mechanic that I'm in good terms with and no tool shop who stocks special tools.
    Grinding a rod cannot be taught. You need an experience. It is not even too easy to grind a rod to this much extent. Grinding is for smaller things. And this is a time taking job. It took me 30~45 min to complete this job. You need to keep water in a mug to cool down the rod every minute because you need to press the rod against wheel very hard and the rod will become ultimate hot in just a few minutes. So you also need to wear hand gloves and glasses because infinite iron particles and sand of wheel will disperse on the air.
    So I not recommend to do oneself if he is a beginner and haven't worked on grinding machine before. I will not be held responsible for anything. Necessary measurement should be taken care by oneself.

    So what I was saying, that you need to press very hard to the wheel and you need to be very careful, if that slip something can go wrong. Keep your hands away from the wheel, hold the rod little bit away from the wheel.
    And what you have to do is to use your eyes and give it a shape like this.



    And on the other side, some go for T shape welding, but I grind it like this and I use adjustable spanner.

    Last edited by paul.1911; 05-09-2013 at 05:06 PM.
    accuengineer likes this.
    Everyone crashes. Some too scared to get back on. Some can't wait to ride again!

    DIY - Foam Air filter Cleaning & Oiling / Horn Repair Guide / Replacing Motorcycle Fork Oil

    Read This Before You Buy Any Halogen Bulb
    Engine Overhaul

  7. #7
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    Default Re: How to Replace Motorcycle Fork Oil [Fork Reconditioning]

    This just sparked an idea inside me (Thanks to Minto Fresh ), How about getting the rod forged by a blacksmith and then filing to shape? I am not new to power tools, I was actually looking for the dimension of the rod. Also how about welding 3 or 4 no. 20 nuts to one end so a torque wrench can be used?

    Slightly off-topic, I just noticed your handle, are you a gun nut, just like me?

  8. #8
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    Default Re: How to Replace Motorcycle Fork Oil [Fork Reconditioning]

    Yes you can go for blacksmith idea. The inner dia of that piston is 9.5~10 mm. So your rod square shape has to be more & less forming 10 mm in the middle. It can be different for different manufacturer. Dimension of rod is already mentioned in my fist post #4.
    Why to weld nuts. Simply weld as T shape because this rod is actually used only to hold the piston. On the other hand, you were using Allen key to tighten the bolt. So torque wrench is to be use on Allen key bolt.
    accuengineer likes this.
    Everyone crashes. Some too scared to get back on. Some can't wait to ride again!

    DIY - Foam Air filter Cleaning & Oiling / Horn Repair Guide / Replacing Motorcycle Fork Oil

    Read This Before You Buy Any Halogen Bulb
    Engine Overhaul

  9. #9
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    Default Re: How to Replace Motorcycle Fork Oil [Fork Reconditioning]

    An easy alternative is to get a suitable sized nut welded to a 12mm rod.
    I had picked up a 30" rod for Rs.25 from a scrap yard and got a nut welded for Rs.20/-

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    Default Re: How to Replace Motorcycle Fork Oil [Fork Reconditioning]

    I have 2009 Pulsar 180 UG 4. I thought of welding with a nut but later I thought it won't be strong so with a creative idea I made a 15.5 mm custom hex rod Allen T spanner to remove the bottom nut with a 6mm allen key while holding the top rod with hex spanner. I successfully removed all the respective parts in order and replaced with a new oil seal followed by new Bajaj fork oil. I poured 320 ml per fork as recommended in the user manual. It took 4 bottles each of 160 ml priced at Rs 44 each. 1 oil seal price is Rs 69.
    Attached Images Attached Images         
    Pinaki, dux, akshatajeya and 3 others like this.

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