Join Date: Mar 2005
Location: Spring Lake, MI
Re: Fork Oil Replacement Step by Step AN650
One thing that I encountered that I should mention:
As noted in Allwalk's instructions, the fork cap is under spring pressure. When you release it it wants to pop up. I knew this in advance, so I had the lower end of the fork on the ground and put downward pressure on the cap with the 17mm allen wrench as I removed it. However, it still 'popped' a little as it finally released; I didn't have enough pressure on it at the end. The cap is aluminum, and the fork tube is steel. When the cap popped, a small amount of the tips of the last few threads of the aluminum cap got sheared off, so there were some metal shavings in the top of the fork.
So the moral of the story is: keep CONTINUOUS downward pressure on the cap until you know for sure it's completely released. Hard to do. Even when I knew to pay more attention on the second fork, there were still a few bits of aluminum there.
The amount of the threads that were removed was minimal, so I'm not worried about the cap. I just didn't like the metal shavings going down into the fork. This may be one argument for pulling the fork completely, rather than using a vacuum pump to suck the oil out. Dumping the oil out would remove the shavings.
2005 Burgman 650|silver|50mpg|25k miles
2010 VW Jetta Sportwagen TDI|silver|42mpg|56k miles
2000 VW Golf TDI (diesel)|45mpg|sold at 284k miles