narow37
Angry Southern White Man
1.) Remove fork brace and front fender. I put the fork brace back on to help keep everything tied together once the front end was off.
2.) Get the bike up on the stand and secure. Seeing as how we are taking the front end off, I put a styrofoam block under the back wheel to stop the bike from rotating backwards from loss of weight on the front of the bike. I also covered the tank and rear fender with towels.
3.) Remove caliper(make note of any shims and where they go) and hang from somewhere on the bike(I used the clutch cable retainers on the frame) so you don't stress the fittings on the caliper.
4.) I lubed up the upper portion of the legs so they would slide through the trees easily. I used my royal purple motor oil, doesn't take much.
5.) Place some tape around the Fork Tube Cap to protect against scratches.
6.) Remove Fork Tube Caps with 1 3/8" socket. At this point an extra set of hands will help. Next, remove the pinch bolts on the back of the lower tree.
7.) Hold both legs just below the lower tree and place a little pressure on the lower tree with thumbs. The legs should start to slide downward. Once you have the whole front end off, put the Fork Tube Caps back in place. I did this so I could drain one leg at a time.
8.) Carefully flip the front end over. I placed one leg on a towel and one in the bucket. Unscrew the Tube Cap and let oil drain out. You may have to pump the shock to get all the oil to drain out. Repeat for other leg.
9.) Take the fork tube caps back off and if needed, relube the upper legs. Carefully slide the legs back up through the trees and replace the Fork Tube Caps and snug them up. Replace the Pinch bolts and snug them up. Not too tight yet, just so the legs don't move on you.
10.) Measure out 10oz. of fork oil. PJ1 30w fork oil is what the Shop Manual calls for. Remove Fork Tube Cap and carefully pour oil in to th top of the leg. Repeat for other leg.
11.) Replace Fork Tube Caps and torque to 50ft-lbs. Torque all pinch bolts to 16ft-lbs.
12.) Replace caliper with shims in correct place. Use red loctight and torque to 39 ft-lbs.
13.) Remove bike from stand and double check all Torque specs.
14.) Remove Fork brace, Replace Fender, Replace fork brace using Red Loctight on the bolts. Clean Up the bike.
15.) Go for a short test ride and double check all torque specs again.
This procedure took my dad and I about 2.5 hours to complete, but we were being very careful and "clean". Gasman, please add to this "How to" as you see fit or you can make your own if you want. I know that everyone was saying the the old fluid really smelled bad but, mine didn't really smell at all.
2.) Get the bike up on the stand and secure. Seeing as how we are taking the front end off, I put a styrofoam block under the back wheel to stop the bike from rotating backwards from loss of weight on the front of the bike. I also covered the tank and rear fender with towels.
3.) Remove caliper(make note of any shims and where they go) and hang from somewhere on the bike(I used the clutch cable retainers on the frame) so you don't stress the fittings on the caliper.
4.) I lubed up the upper portion of the legs so they would slide through the trees easily. I used my royal purple motor oil, doesn't take much.
5.) Place some tape around the Fork Tube Cap to protect against scratches.
6.) Remove Fork Tube Caps with 1 3/8" socket. At this point an extra set of hands will help. Next, remove the pinch bolts on the back of the lower tree.
7.) Hold both legs just below the lower tree and place a little pressure on the lower tree with thumbs. The legs should start to slide downward. Once you have the whole front end off, put the Fork Tube Caps back in place. I did this so I could drain one leg at a time.
8.) Carefully flip the front end over. I placed one leg on a towel and one in the bucket. Unscrew the Tube Cap and let oil drain out. You may have to pump the shock to get all the oil to drain out. Repeat for other leg.
9.) Take the fork tube caps back off and if needed, relube the upper legs. Carefully slide the legs back up through the trees and replace the Fork Tube Caps and snug them up. Replace the Pinch bolts and snug them up. Not too tight yet, just so the legs don't move on you.
10.) Measure out 10oz. of fork oil. PJ1 30w fork oil is what the Shop Manual calls for. Remove Fork Tube Cap and carefully pour oil in to th top of the leg. Repeat for other leg.
11.) Replace Fork Tube Caps and torque to 50ft-lbs. Torque all pinch bolts to 16ft-lbs.
12.) Replace caliper with shims in correct place. Use red loctight and torque to 39 ft-lbs.
13.) Remove bike from stand and double check all Torque specs.
14.) Remove Fork brace, Replace Fender, Replace fork brace using Red Loctight on the bolts. Clean Up the bike.
15.) Go for a short test ride and double check all torque specs again.
This procedure took my dad and I about 2.5 hours to complete, but we were being very careful and "clean". Gasman, please add to this "How to" as you see fit or you can make your own if you want. I know that everyone was saying the the old fluid really smelled bad but, mine didn't really smell at all.
:roll: :roll: :roll: 
