900 fork oil replacement

[hp10a10]

Hi all,
I am newbie with diversion so I hope this is the correct place for my post.

Firstly I was wondering what is the correct amount of oli to be put in the fork. I found info from ´95 service manual that it is 441cm3. Mine is 2002, i dont know if this applies also for my bike?

The next question is that would it possible to change fork oil if I dont like to remove fork from the chassis.

I took a look at the picture I found from the ´95 service manual but I cant figure our if any of those parts is drain plug. Is there one?

Will I run into the problems if I try to do this without removing fork? Is it difficult to remove the cap on top of tubes? In my bike there is preload adjustment, does this make difference for oil change?

Thanks in advance!

Attachments:

[bobh]

There is no drain plug, so the fork legs have to be removed to get the oil out. If it's been in for any length of time it will be quite contaminated, and you may want to flush the forks out with light oil before refilling.

It's not difficult to remove the cap, provided you loosen it while the leg is still mounted on the bike. It's a lot more difficult to screw it back in afterwards, because of the spring - make sure you've backed the preload right off. Then finally tighten the cap after the leg is reinstalled and clamped in place.

As to the amount of oil, I think it's better and easier to fill it up to the level rather than measuring out a quantity.

If you don't have one already, I'd recommend you get a Haynes manualone, as it covers all this sort of work in great detail.

[hp10a10]

Thanks bobh for this!

I heard that some guys has done this so that they sucked old oil from above with suction pump like in picture in link below.

www2.westfalia.net/medien/scaled_pix/250/180/000/000/000/000/000/019/98.jpg

Does anyone have idea is that way good or not? Anyway on this way you dont have to remove fork from chassis I guess.

[doyle]

I've just removed my D9 forks, replaced the oil, and will fit back on the bike this week. I'm almost certain a suction pump will not remove all the old oil. Removing the forks gives you a chance to do some maintenance and check some components......

1: A thorough check and clean of the forks.
2: Front wheel bearings inspect and change as req'd.
3: Front brakes inspection and maintenance as req'd.
4: Steering head bearing inspection best done with the forks removed. Good chance they'll need some attention.
5: Have a good look at cables, speedo cable, electricals etc.

And as BobH suggests, investing in a Haynes manual will help no end. BTW, fork oil capacity is 441cc per fork.

Hope this helps, and good luck.



Cheers

Greg

[Ol' Greasy Dave]

an easy way to replace the fork caps is to buy an el cheapo rubber mallet - take the handle off, get a stanley knife (or similar) & cut an indentation the same size as the nut on the fork cap

put this indentation over the cap & you then have plenty of leverage to screw the cap in nice & easy

[CD]

Also loosen the top yoke clamp bolts before/after you remove/replace fork leg the top plugs. There is enough clamping force to fully lock the threads.

Be careful when you unscrew the plugs as the springs will pop out with the spacing washers.