Question about 2005 Enfield Bullet Machismo

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Check oil level in front shocks

Want to make sure I do it right. I think I have a bad seal at top end of fork tube where it meets headlight casing tube. Repair manual alittle confusing. Sez use 5MM rod

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How long? Also sez level height 370-380mm from where? I guess I'll get a 3/16 dowel stick (5mm = .196) from hardware store. Also oil type shop manual sez 10w-30. Snidel sez 20-20w or ATF. Just making sure.straighten out a clothes hanger and stick it in until it bottoms.  If both sides are the same I'd say you were OK.  If not drain and refill with whatever you intend to use, it really doesn't make much difference.,,,

Posted on Nov 10, 2008

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SOURCE: check oil level in front shocks

how long? Also sez level height 370-380mm from where? I guess I'll get a 3/16 dowel stick (5mm = .196) from hardware store. Also oil type shop manual sez 10w-30. Snidel sez 20-20w or ATF. Just making sure.straighten out a clothes hanger and stick it in until it bottoms.  If both sides are the same I'd say you were OK.  If not drain and refill with whatever you intend to use, it really doesn't make much difference.,,,

Posted on Nov 10, 2008

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Change fork oil street bob 2007


To change the oil or to rebuild a 2007 DYNA front fork FIRST raise and support the motorcycle so that the front end is off the floor and the forks are fully extended, remove the brake caliper and the front wheel, remove the front fender, loosen the pinch bolt screws, do not remove the tube caps, slide the fork sides downward clear of the fork brackets, repeat the procedure for the opposite fork tube and slider assembly.

To disassemble a 2007 DYNA front fork clamp the fork tube and slider assembly in a fork tube holder tool mounted horizontally in a vise, use a 12mm Allen wrench is needed to loosen but do not remove the seat pipe screw, while the internal components are still under tension and less prone to rotate, on the right fork tube and slider assembly, remove the axle holder to access the seat pipe screw, remove the fork tube cap and its o-ring, remove the long spring collar, remove the fork assembly from the fork tube holder tool and invert it over a suitable container to catch the fork oil and allowing thefork to drain, extend and retract the slider several times to push oil out of the internal fork components, the washer, and the spring will fall out of fork tube. THEN clamp the fork tube in the fork tube holder tool, remove the slider cover from the slider by inserting a brass drift into the notch in the slider and lightly tapping the cover loose, compress the stopper ring and remove the stopper ring from the groove in the top of the slider bore, Do not remove slider tube caps without relieving the spring preload or the caps and springs may fly out. THEN remove the seat pipe screw and its washer from the bottom of the slider and retain them for reuse, withdraw the slider from the fork tube until the bushing guide contacts the bushing on the fork tube (the bushing guide is a slight interference fit in the slider), then using the slider as a slide hammer, hit the bushing with the bushing guide with a quick continuous stroke until the slider is pulled free from the fork tube, drain the slider and allow the stop oil lock piece to fall free. (If you are only changing the oil or replacing the slider the remaining parts can be left assembled and the fork re-assembled) If it is still attached to the seat pipe remove the stop oil lock piece from the lower end of the seat pipe, remove the seat pipe piston and the ring assembly, remove the rebound spring, remove the oil seal, remove the seal spacer, and remove the bushing guide. Repeat the foregoing procedure for the opposite fork tube and slider assembly.

Thoroughly clean and inspect each part and if and as necessary replace any corroded, worn, bent, broken or otherwise damaged parts, inspect the fork tube bushing and the slider guide bushing and replace if and as required, always replace all oil seals and all o-rings, check the dust cover where it rubs on the fork tube (it should have a good and continuous seal and not show excessive wear, check the fork tube where it rubs on dust the cover and the tube should show a bright, shiny surface, free of scoring or abrasions, if any spring(s) is/are broken they must be replaced, if a fork tube or slider is bent or damaged it must also be replaced now, replace all other worn or damaged components if and as necessary.

To assemble a 2007 DYNA fork FIRST insert the seat pipe assembly with the spring into the slider tube, slide the bushing guide down to the bushing on the fork tube, follow it with the spacer, the oil seal, the stopper ring, the dust shield and the slider cover, install the fork tube into the fork tube holder tool, fit the lower stop onto the seat pipe, slide the seat pipe back into the fork tube until the seat pipe is centered in the tube, gently install the slider assembly onto the slider tube and the bushing, thread the seat pipe screw and washer into the seat pipe through the bottom of the slider assembly, draw the fastener into the seat pipe but do not tighten it at this time, verify the proper action of the fork by moving the slider up and down the fork tube, locate the appropriate fork seal driver over the fork tube in front of the oil seal with the fork seal chamfered lips facing the oil in the fork, in the following order assemble thetop oil seal, the spacer and the bushing guide into the slider bore, install the stopper ring into its groove above the oil seal, push the dust seal against the oil seal and stopper ring, rotate the slider cover to match any removal burrs to the notch in the slider and snap the slider cover into place. THEN operate the slider through its full range of travel several times to verify alignment and proper smooth operation, then pulling down on the slide to apply downward force on the rebound spring, tighten the seat pipe screw to 106-159 in-lbs (12-18 Nm), vertically re-position the fork tube into the fork tube holder tool and with the slider tube compressed, fill the fork with Harley-Davidson TYPE E FORK OIL until it is approximately the amount specified below for the type or motorcycle and fork that it is.

a. FXDWG- approximately 29.6 oz (875 cc) and distance from the top of the fork tube = 4.4 in (112 mm); and
b. All other Dyna models- approximately 26.6 oz (787 cc) and distance from the top of the fork tube = 4.3 in (110 mm)
THEN slowly pump the slider 8 to 10 times to remove air from the fork assembly and fully compress the slider to properly measure the oil level which is measured from the top of the fork tube, with the spacer and the spring removed and the fork fully compressed, then using an appropriate oil level gauge tool adjust the oil level to appropriate level for the fork type and model, pull out the slider and install the spring in the fork tube with the tightly wound end at the bottom, install the washer and the spring collar, carefully to avoid cross threading, install the fork tube cap with a new o-ring and tighten it to 16-43 ft-lbs (22-58 Nm). Repeat the process for the other fork tube and slider assembly.

To install the fork in a 2007 DYNA FIRST insert the fork tube and the slider assemblies up through the lower triple clamp and the upper triple clamp so that the fork tubes will protrude above the upper triple clamp 0.450-0.500 in. (11.4-12.7 mm) with the measurement taken at the midpoint of the fork tube between the top surface of the triple clamp and the top of the fork cap and when properly positioned tighten the pinch bolts to 30-35 ft-lbs (41- 48 Nm), install the front fender and bracket, install the front brake caliper(s), install the front wheel and align the wheel to the forks.

May 11, 2014 | 2006 Harley Davidson FXDBI Street Bob

1 Answer

Front shock oil running all over


Unless you've had your front fork assembly serviced recently, I'd guess you've got blown oil seals in the top of the sliders on your forks. If someone serviced your forks lately, they may have put in too much oil and blown the seals. You'll have to drain the forks, disassemble the fork tube from the lower slider and replace the seal in each leaking tube. Refill the fork tube with the designated about of oil for a "dry" refill. Use this figure because the fork tube was disassembled. When you simply drain the forks without a disassembly, you cannot get all the oil out and the refill quantity is less.

Good Luck
Steve

Aug 06, 2011 | Harley Davidson FLSTC Heritage Softail...

1 Answer

Keep having leaking fork seals.have replaced seals and oil after every ride lately.(4)have tried two brands of seals last time disasembled whole of forks cleaned every part,shims everything and had...


G'day. A couple of suggestions-
Damage to the fork slider-chips or dings.
Too much oil in the fork on re-assembly can cause the seal to go.
Worn or loose fork bushes will flog the seal prematurely.
When you transport the bike-if you don't use a seal saver can pop the seals.

So let me help with these.

Be sure that the fork slider is not scored,dinged or damaged on th surface.

A good double check of the oil quantity is to ensure that when you have re-filled the tube with oil & primed it(worked the air out of it), the oil level should be 100 to 110 mm from the top of the leg to the oil with the fork fully compressed. If the level is less than this-drop it to 100mm.

To check the fork bushes-try pull on the front forks front to back(wobble) & feel for looseness in the bushes.

And finally-When you transport the bike-put a chock(I use an empty 5ltr oil container-but you can buy propper chocks from the bike shop) in-between the forks at top of the front wheel .
Now when you pull the front end down it will stop on the chock & stop the front forks being under excessive compression for extended periods-so it saves the fork springs from sacking out too.
I hope this proves helpfull.
Kind regards Andrew Porrelli

May 20, 2011 | Sherco 5.1i Motorcycles

1 Answer

I need instructions to replace fork seals on a 1988 h.d. flst.


First you must remove the windshield, front fender, headlight nachelle, and front wheel. Get everything off the front end. Then, take the top cap off of one fork tube at a time. I do this with it still in the front end just in case it's real tight. Once I get the top cap lossened and remvoved, I break the torque on the pinch bolt on the lower triple tree and remove the entire fork tube. With the tube off, I remove the spring and pour out all the oil. Make sure you look at the sping as you take it out, One end is different from the other and you want it back in the correct way. Now, with the oil and spring out, look at the lower end of the tube where the axle is held into the lower slider. You'll see a socket head bolt. This bolt takes an 8mm hex key. I use an air wrench to take this bolt out. Once you've got the bolt out, the inner fork tube will pull up and out of the lower slider. Pull off the rubber boot and there's snap ring just inside the top end of the slider. Remove this and pry out the old seal noting which direction the seal is facing. They go in with the lip facing down. Install the new seal and reassemble the fork tube. Install this tube on the bike, add the proper quantity of oil, install the spring and top cap, and retighten the pinch bolt on the lower triple tree. Then, do the other side the same way. Reassemble all parts taken off. Note: Reinstalling the top cap on some models can be pretty tough and my require a special frok spring compressor. Good Luck.

Feb 06, 2010 | Harley Davidson FLSTC Heritage Softail...

1 Answer

What is the fork oil amount for a 2002 klx 300 per fork tube


The owners manual says to do the following if you don't want to remove the forks:
*raise the front wheel
*remove the fender, meter cable & unit, headlight, handle bar, fork protectors
*loosen the fork upper clamp bolts
*remove the caps from the top of the fork tube
*fully compress the fork tube so the dust cover touches the bottom and place a stand to hold it
*remove the springs
*set the oil level 68mm (standard) or 60 - 90 mm (adjustable) from the top of the tube

It may be easier to remove the tubes and you could replace the leaky seal at the same time. I did this recently and put in new springs too. It was my first time working on forks. With help from TT members and the service manual it was fairly easy. I didn't buy an oil gauge, seal driver, or spring holder. I used a ruler to measure the oil and a medicine dropper to remove any excess. For a seal driver I used a piece of PVC pipe cut in half then secured around the lower tube to drive the seal. Try a search on replacing fork seals for more info. 5w oil is standard but i have heard that 7 works well Good luck.

Dec 20, 2009 | 2002 kawasaki KLX 300 R

3 Answers

I need to know the oil capacity of the front forks on my 1999 Suzuki Marauder VZ800.


FORK OIL
• Place the front fork vertically without spring.
• Compress it fully.
• Pour specified front fork oil up to the top level of the outer
tube.
Capacity (each leg): 490 ml (16.6/17.3 US/lmp oz)
99000-99044-L01: SUZUKI FORK OIL L01
or an equivalent fork oil
• Move the inner rod slowly with the special tool ten times and
more until no more bubbles come out from the oil.
09940-52841: Inner rod holder
NOTE:
Refill front fork oil up to the top of the outer tube so that bubbles
are visible while bleeding air.
• Refill specified front fork oil up to the top level of the outer
tube again. Move the outer tube up and down several strokes
until no more bubbles come out from the oil.
• Keep the front fork vertically and wait 5 – 6 minutes.
NOTE:
* Always keep oil level over the cartridge top end, or air may
enter the cartridge during this procedure.
* Take extreme care so as to pump out air completely.
• Hold the front fork vertically and adjust fork oil level with the
special tool.
NOTE:
When adjusting the fork oil level, compress the outer tube fully
without the fork spring.
Fork oil level: 153 mm (6.02 in)
09943-74111: Front fork oil level gauge

Dec 18, 2009 | 1998 Suzuki VZ 800 Marauder

2 Answers

How to fill the front suspension on a ktm exc 2001


If you get the sevice manual or contact a dealer to get the correct oil amount for your bike, they need to know the model and year, you have to have the forks off the bike. take the fork caps off, take the springs out compress the upper fork tube all the way and add the specified oil. if they also give you the measured amount from the top that's the best way to get both fork oil levels exact. there is a special tool that you set the oil level in millimeters and it sucks out the oil to the right level, but before you do that step after adding the oil always pull and push on the cartage rod several times to remove air from the cartage tube. you will hear the air coming out and you will feel the changes in the cartage rod as the cartage tube fills up with oil and the air is removed.
something i'm confussed on though is if you replaced a seal you would have had to brake down the fork to replace it. you would have poored the oil into a container, cleaned all the internal parts,and used a fork seal driver to install the new seal. part of your question asks where do i put the oil in? thats in the open end of the fork after you have taken off the fork cap. It sounds to me like you only replaced the dust seal on one fork. that is not going to fix your leaking fork. you need to replace the oil seal thats pressed inside of the top fork tube.

Dec 01, 2008 | 2008 KTM 200 EXC

1 Answer

Right front fork seal bad? Oil mess


got away from rear break usage due to weird squealing which I've read about. The book says to use front brake as much as possible but puts downward load on front shocks alot. Damn Injuns. Sorry for the vent its a putter but the wife is asking why is it apart more than on the road. The wife I can fix the bike I need help.I'd replace the O-ring on the cap on top of the fork tube first. The turn signal is kinda high to be getting oil on it from a fork seal leaking.,,

Nov 10, 2008 | 2004 Enfield Bullet Sixty-5

1 Answer

Check oil level in front shocks


how long? Also sez level height 370-380mm from where? I guess I'll get a 3/16 dowel stick (5mm = .196) from hardware store. Also oil type shop manual sez 10w-30. Snidel sez 20-20w or ATF. Just making sure.straighten out a clothes hanger and stick it in until it bottoms.  If both sides are the same I'd say you were OK.  If not drain and refill with whatever you intend to use, it really doesn't make much difference.,,,

Nov 10, 2008 | 2005 Enfield Bullet Sixty-5

1 Answer

Right front fork seal bad? Oil mess


got away from rear break usage due to weird squealing which I've read about. The book says to use front brake as much as possible but puts downward load on front shocks alot. Damn Injuns. Sorry for the vent its a putter but the wife is asking why is it apart more than on the road. The wife I can fix the bike I need help.I'd replace the O-ring on the cap on top of the fork tube first. The turn signal is kinda high to be getting oil on it from a fork seal leaking.,,

Nov 10, 2008 | 2006 Enfield Bullet Machismo

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