Hi again everyone

Next job - fork seals. Found liquid on brake caliper, but it's not brake fluid. Looks like it's coming from fork seal (left side). Am going to replace the seals.

May be a dumb question - in the manual it shows:
Fork oil level 173 (6.8) - where is this measured?
Fork oil capacity 418cc - is it 418cc in each fork?

Unsure how much oil has leaked from the left fork, and whether any has leaked from the right, so thought it best to ask!

Thanks all.

 

Fork oil level 173 (6.8) - where is this measured?
Fork should be upright, no spring, fork tube fully closed
Make sure you pump the damper rod in and out a few times to make sure the damper is full before taking the reading


Fork oil capacity 418cc - is it 418cc in each fork?
Yes - this is the approx amount of oil in each leg ( air gap is a more accurate measurement )

 

Clarification, 173mm or 6.8 inches from the top of the oil to the top of the fork tube when fully compressed and spring out. You are measuring the air above the oil.

Best way is to mark a tube or small stiff hose 173mm from the end and slightly over fill the fork tube. Place the hose into the fork tube and aline the mark to the top of the fork tube. Place your thumb over the end of the hose and remove any extra oil. It may take a few tries. I use a vacuum brake bleeder to suck the extra oil out.

 

One of the fork top caps won't loosen. Fork still in yoke. Have jammed a nut into the end of the spark plug tool to stop it deforming, but it has deformed the hex socket in the fork cap instead.
Anyone got any suggestions?
Thanks!

Not doing too well on this job. As well as the problem with the fork cap, I've rounded off one of the brake caliper bolts and one of the mudguard bolts. Thankfully managed to get them out.

 

WD40 goes a lot further than brute force. Try giving the cap a few smacks with a rubber mallet to jolt the thread a bit

 

Sounds like you need to invest in an impact driver.

 

Or if it's twisted enough and ya figure you'd have to replace it anyhow

then loosen the handle bar so the fork top is free and clear then get a
big arsed plumbers pipe wrench and show that cap who's Boss !

Grab a another good cap from ebay or the knackers yard

 

Yup, that's my next move!

 

if you have access to a 3/8 impact gun with a strong air compressor and I believe it’s 6 mm or 8 mm Allen socket, pulling up on the damping rod, you blip the gun 6-7-8-9- times boom, boom, boom and they always come out if you don’t have these tools, you can buy the tool from RACETECH which holds the damping rod and it allows you to unscrew that Allen bolt/anchor bolt. Where do you live? I could get these out for you in a minute for free..

 

Use a heat gun if the caps wont break loose…
heat the outer fork seal area before using the slide hammer technic to separate the tubes, this usually can prevent having to teplace the bushing(if not worn out) . Good luck…