Front Fork Oil

[markmartin]

Pay extra attention when replacing the fork cap and the attached damper adjuster rod assembly.  The D shaped rod fits in the middle of the damper rod, BUT, it's possible to assemble it with the rod off to the side.  DAMHIKIJK.  You'll know if it's wrong because your forks will barely compress as you'll be trying to bend that rod.   It's nothing to worry about, just something to be aware of.

Mark

[chapindad]

I can not find a 18mm bolt around here.   Did you all order them?

[Mark Olson]

use the nut off your rear axle .

[Mike 86 in San Dimas]

Since you have the rear axle nut off....

[chapindad]

I actually finally found a 18mm bolt and made me a tool.  All is well until I went to put it back on.  I can not get the cap to go down so that I can screw it on.  What am I missing?  Also which way does the spring go?  I noticed that one side is more compressed than the other.  Is the compressed side on the bottom or top.  I can not seem to find any pictures showing the direction.

BTW, The field service manual is terrible compared to my corvette field service manual.

[markmartin]

 I can not get the cap to go down so that I can screw it on.  What am I missing?  

It's probably D shaped rod (attached to the cap) that is not properly fitting into the D shaped receptor in the top of the damper rod.

Remove the spring, and using a flashlight look down into the fork tube.  About a foot down or so, you should see the top of the damper rod.  It has a D shaped hole in the middle, surrounded by slots on the outer perimeter. (going by memory here..)   The rod has to be oriented to fit down into the D shaped hole.  The rod can go into the side holes and lead you to believe you've got it right, but then it just doesn't work.

That's where I'd start.

[chapindad]

That was it.  But let me admit to being stupid on why it was being a pain to get it in straight.  The collar bolt on the handle bars was in very tight and i could not break it when I first started so I just left the handle bars on thinking I had enough room to get them out and I did.  Getting things to line up with them on is about impossible.  I was able to finely break the collar bolt and got the handle bars off.  It still took a few minuts to line up the D Rod, but everything was simple after that. 

THANKS for ALL the HELP!

I was able to replace the front wheel bearings, front brake pads and the fork oil. 

[chapindad]

Got to take the bike into work today and WOW what a difference all that made.  I can stop on a dime and turn around it at the same time.  Changing the fork oil will be a yearly maintenance item for me and THANKS to all those that helped me through the process....

[markmartin]

You're welcome.  Only passing on information I received from members of this forum when I was working on mine.  I got through my project the same way.  Great forum huh?