Front fork maintence-clear-oil change

[de dee]

 I changed the fork oil on tue.  on the downtown, remove  the top cap , then push down on the top , it is spring loaded,  and it is held in with a small ring, push down on the center the side should pop up and pull it out, then wiggle the plug out,drain the oil out, and the spring slides out, put the spring back in and put 185 ml. # 10 fork oil in,put the plug in and compress plug in and replace spring clip, all done!!!   you need three hands to put spring clip in, one too hold shock from compressing, one to push down on plug, and one to install clip,.  I have a carpenters vice, thats one hand, it has wood face so it will not crush tube

[Adept]

I find a cap on the top of the fork, not a screw...
How can I take that out?

Now I drained the oil by unscrew the bottom allen screw, and pull apart the fork. I filled up with oil, but now it knocking up (I don't know the english phrase)... Should I fill more oil in it??

[bman]

If you can the easiest way is to take out the top mounting bolt on each fork leg. Loosen the bottom ones slightly, to take pressure off the cap, then loosen top cap with allen wrench while forks are still on bike.
Remove fork mounting bolts and remove the forks.
Take off the cap, being careful as it is under spring pressure.
Remove spring and drain forks by turning them upside down.
I use this http://www.chaparral-racing.com/product/pro-honda-suspension-fluid-ss-8-10w/19-1024.aspx.
Fill the correct amount and move the forks up and down to release any trapped air.
Put in spring and put cap back on hand tight.
Forks back on bike, snug up bottom mounting bolts, torque caps, put top mounting bolts back in and tighten everything up.

[Adept]

Yes, I found descriptions on the net too, but now I need practical advice.
What tool can grap that cap? How you take it out???

[de dee]

 
  the plastic cap comes off with a knife, pry it a little and it come off easy,   the plug is harder you have to push down on it and get the little spring clip out, push down on the middle of the --C  and the ends pop up, 

[Adept]

 
  the plastic cap comes off with a knife, pry it a little and it come off easy,   the plug is harder you have to push down on it and get the little spring clip out, push down on the middle of the --C  and the ends pop up,

Infinite beers for you!!!!

I pushed down very hard (my fingers are healing well thank you). So there is a circlip in it, I took that out. It pushed out some oil, so I have to drain down all of it, so I can measure exactly the 185ml...

One final question. In the first round I put 185ml in the fork, and I was still weak, couldn't hold the weight of the bike.

What should I do now? I drain the oil, I fill it up, push it a few time to push out the air bubbles, I close with the cap. Is there any trick??

[Adept]

I have done everything, but still too soft. The fork can't hold the weight of the bike...

Is it possible It needs more oil? What could be the problem???

[de dee]

  the springs could be too short, I have a set of springs coming in on the 8th of may I will post the measurments of the springs,  how much does your springs compress when you sit on your scoot, the book says there is 4 1/2 inches of compression,  total,  I am 220 lb. and I think it goes down 1 1/2 inches when I sit ,  and the other thing I will do is try # 15 shock oil,.  also I will compress spring 4 inches on a scale to see the diference with new springs and old springs,.  any other thoughts??

[Adept]

So we are in the same weight category (I mean featherweight  )

The funny thing is my fork was all right before this oil change, I just tought I needed a new oil after 4 years... So it must be an assembly problem, not a broken part in it or something like that.

[Adept]

Okay I have fix a lot again... I have a theory...

In this fork, there is not a screw, but this sh**ty cap, what you have to push down very hard to put its place (and after that the circlip)
So if I don't hold against the rod hardly, while I push down the cap, I press a little air out, and I already lost some pressure, the fork will be shorter, and softer...
If there would be a screw it wasn't a problem.

I hope you get it...

[de dee]

  I dont know if the air makes any difference,. I hung the shock from my vice, so it was fully extended, when I put the top plug in,.  I over filled ,I put 190 ml. in the shock, and the ride is so much better,.  the factory only put 160 ml. in,. I did not see a leak,. 

[Adept]

Wait, wait...
The factory quantity is 185ml in the manual, not 160...

[de dee]

  only 160 ml. measured, must have been friday 5 oclock when my scooter was filled, in a hurry to go home, 

[Adept]

De dee, will you use any spring preload?? I think about a1 inch metal ring (spacer?) what I would put between the metal cap and the spring. That would give a little preload to the spring. The question what size would be fine? I tought I make 2 smaller pieces per rod, so I can try a little.

What did you say, how many inches the normal compression of the spring under our weight??

[de dee]

  good question ,  I just got someone to measure and it is 3/4 inch, so that leaves 3 3/4 inch ,  how much does your scoot compress