Question about 1998 kawasaki VN 1500 Vulcan Classic Tourer

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How can I tell if my Fork tubes take fork tube oil or are Air ride....I don't seem to see the normal drain plugs for the fork tubes.

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Most forks take Automatic Transmission oil ("ATF").
Most new motorcycles don't have drain holes for it is almost impossible to remove all of the oil through such an opening.
If the forks aren't leaking and are working, don't disturb them. If they are leaking you will need to remove and service them. This should be only done by a shop or someone who knows how.

Posted on Jun 16, 2009

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Hi
Forks without drain holes have to be removed & inverted to get the oil out - A RIGHT PAIN
Those that take air still use oil for damping

Ride Safe
Bike-Doc

Posted on Jun 27, 2009

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How to install lower sliders on 2008 ultra classic


Loosen the fork cap bolt from the fork tube plug at the top of the fork tube, but do not remove it at this time. THEN loosen the pinch bolt (with lockwasher) in the lower fork bracket, but do not remove it. THEN spray glass cleaner like Windex on the fork tube above the rubber fork stop and after so lubricating the surfaces move the fork stop up the fork tube until it contacts the bottom of the upper fork bracket. THEN, while holding the fork slider to prevent the fork from dropping, remove the fork cap bolt from the fork tube plug and slide the fork tube down and out of the upper fork bracket, the fork stop, the lower fork bracket, and the slider cover. THEN thread the fork cap bolt back into the fork tube plug to prevent loss of fork oil while handling the removed fork assembly. THEN move the fork to your work bench area and place a suitable drain pan on the floor underneath your vise. NOW or later you can similarly remove the other fork tube assembly.

IT IS HANDY to have a HD-41177 FORK TUBE HOLDER or similar tool.

On the first fork remove the nuts, the lockwashers, the flat washer and the axle holder from the studs at the end of the fork slider. THEN clamp end of a fork holder tool in your vise in a horizontal position with the tightening fasteners facing toward you and with the fork cap bolt at the top clamp the fork tube in between the rubber pads on the inside of the tool and tighten the fasteners to securely hold the fork tube assembly. THEN remove the fork cap bolt from the fork tube plug and remove and throw away the quad ring seal. Thenslowly unthread the fork tube plug from the fork tube being AWARE that the fork tube plug is under spring pressure which requires you to have a firm grasp on plug as the last thread is turned. THEN remove the O-ring from fork tube plug and throw it away. THEN remove the fork spring from the fork tube and remove the fork assembly from the fork tube holder. THEN turn the fork upside down and drain the fork oil into the drain pan by slowly pumping the fork tube and slider at least ten times being aware that the damper valve, if it has one, may fall out of the inverted fork tube while you are draining it. THEN With the wear ring at the bottom, i.e. with the spring side up, slide the damper valve back into the fork tube when it has been fully drained.

THEN for further disassembly install the fork spring back into the fork tube place a shop rag on the floor, and turn the fork assembly upside down and press the end of spring against the rag. Push down and compress the spring to prevent the damper tube from turning and then remove the6mm screw from end of fork slider with a strong short stroke impact wrench and 12 mm Allen socket adapter for best results. When the screw and washer are removed throw away the 6mm screw and copper crush washer. THEN remove the fork spring, the damper valve (if it has one) and the damper tube from fork tube. THEN remove the wear ring and the rebound spring from the damper tube and it has one, from the damper valve, if it has one. Then without expanding or stretching the retaining clip to avoid it becoming bent or distorted, remove it from the fork tube. THEN, using an appropriate pick tool, remove the retaining clip from between the fork slider and the fork tube and remove the fork tube from the fork slider. Use the fork tube as a slide hammerwith a moderate amount of force until the fork tube separates from the fork slider. THEN slide the fork oil seal, the slider spacer and the slider bushing off of the end of the fork tube and throw away the fork oil seal and the slider bushing. THEN gently pry at the split line to expand the fork leg bushing, and remove it from the groove at the end of the fork tube and throw away the fork leg bushing. THEN remove the lower stop fromthe fork slider.

THEN thoroughly clean and inspect all of the parts. And replace all parts that are bent, broken or otherwise obviously damaged. Inspect the fork cap bolt quad ring seal and the fork tube plug O-ring for cuts, tears or other signs of deterioration and replace whatever is necessary and/or prudent. THEN replace the retaining clip if bent or distorted and check the slider and fork leg bushings for scratches or excessive wear and always replace bushings in a set if either bushing is damaged or worn THEN also check the fork tube and the slider for scoring, scratches and excessive or abnormal wear and replace all parts as necessary and/or prudent. THEN set the fork tube on V-blocks and measure the runout using a dial indicator gauge and replace the fork if runout exceeds 0.008 in. (0.2 mm). THEN inspect the upper fork spring and the rebound spring for damage or distortion and replace the upper fork spring if the free length is less than 18.4 in. (467.3 mm) and replace the rebound spring if its free length is less than 0.938 in. (23.8 mm) or otherwise whenever the upper fork spring requires replacement.
To reassemble the fork coat the fork leg bushing ID with clean fork oil and then expand the fork leg bushing at the split line only so far as required to it slip over the end and into the groove of the fork tube. THEN install a new wear ring in the groove at the top of the damper tube and install the rebound spring on the opposite end. Now, with the wear ring on the top side slide the damper tube into the fork tube, so that the tube end drops through the hole at the bottom of the fork tube. Now install the lower stop at the end of the damper tube and put the fork slider back into your fork tube holder. THEN slide the fork tube into the fork slider. NEXT coat the slider bushing ID with clean fork oil and install the slider bushing down into the fork tube and then slide the slider spacer down the fork tube until it meets the slider bushing and then get your fork oil seal installer tool and it down the fork tube and drive the slider bushing and spacer into the bore of the fork slider and then remove the tool and THEN put some masking tape over the top edge of the fork tube to avoid damaging the lip of the fork oil seal during installation and then coat the new oil seal with new fork oil and install the seal with the garter spring facing into the fork tube and slide it down to the bore of the slider and the earlier installed spacer and then remove the masking tape and with your fork seal installation tool drive the seal down into the top of the slider until you can insert the retaining ring and then again remove the seal driver tool and install the retainer ring into its slider groove. NOW slide the fork spring into the tube and remove the fork assembly from your fork tube holder and with a shop towel or rag on the floor turn the assembly upside down and press the spring against the shop towel or rag and install a new 6mm screw with a new copper crush washer through hole at bottom of fork slider and start to screw it into the end of the damper tube. Continue to compress the spring into the assembly to stop the damper tube from turning and tighten the 6mm screw to 132-216 in-lbs (14.9-24.4 Nm). After this remove the fork spring from the fork tube and again clamp the fork slider (NOT THE FORK TUBE) into your fork holder tool with the fork tube on the top side and if it was previously removed install the drain plug at the bottom of the fork slider and tighten it to 72-96 in-lbs (8-11 Nm).

THEN refill with the correct amount of fork oil. It is very important for the correct and safe operation of the bike that the CORRECT amount of oil be installed. FOLLOW the correct procedures for doing this.

Aug 10, 2014 | Harley Davidson FLHTCUI Electra Glide...

1 Answer

How to change fork oil


Take the weight off the front wheel, remove the big nut at the top of the forks, at the bottom of the forks you will see a small bolt head, this is the drain plug for the fork. Remove the plug and drain the old fluid out of the forks then replace the plugs before filling the tubes with the new fluid. Make sure you put exactly the right amount back in the tubes or you will have either a spongy ride ( not enough oil ) or a hard ride due to too much oil.

Aug 06, 2014 | Harley Davidson FLSTC Heritage Softail...

1 Answer

How to replace fork seals 2007 fatboy


To replace the front fork oil first support the motorcycle so the front end is off the floor and the forks are fully extended. Remember that the FLSTC and FLSTF models have a preloaded fork spring and that the fork tube plug is under spring pressure.Then you remove the fork tube caps. And then you drain the fork oil. ON FXSTD models, your remove the drain screws and washers from each fork and drain the fork oil this way. ON ALL MODELS EXCEPT the FXSTD, remove and discard the drain screws and washers from each fork and drain the fork oil and then you install new drain screws and washers. ON FXSTD models, apply LOCTITE THREADLOCKER 243 (blue) to the drain screws and tighten them to 12-18 inlbs (1.4-2.0 Nm). ON ALL MODELS EXCEPT FXSTD, tighten the drain screws to 52-78 in-lbs (5.9-8.9 Nm).THEN fill the fork with Harley-Davidson TYPE E FORK OIL (Part No. HD-99884-80).Either by installing oz or cc's of fluid if the forks were left in the frame or by measuring the amount of oil in the tubes in inches or mm if the forks were removed from the frame and disassembled. In the latter case the oil level is measured from the top of the fork tube with the spring removed and the fork fully compressed.

MODELs FLSTC, FLSTN use 13.4 OZ 395 cc4.41 inches 112.0 mm
MODEL FLSTF uses 13.4 OZ 397 cc5.04 inches128.0 mm
MODELs FXST, FXSTB, FXSTC use 12.5 OZ370 cc 6.69 inches170.0 mm
MODEL FXSTD uses 11.6 OZ343 cc 7.48 inches190.0 mm

FINALLY tighten the fork tube caps to 40-60 ft-lbs (54.2-81.3 Nm).

Jul 10, 2014 | 1993 Harley Davidson FLSTF Fat boy

1 Answer

How do i rebuild 41mm forks


Depends on how much rebuilding you want to do.
See below:

FRONT FORK 2.16
CHANGING FORK OIL On a 2010 Touring Motorcycle 41 mm Fork
If only replacing the fork oil remove the for, clamp a fork holder tool in a vise in a horizontal position and with the fork cap bolt topside securely clamp the fork into the tool, remove the fork cap bolt, remove and discard the quad ring seal, carefully remove the fork tube plug from the fork tube and because it is under strong spring pressure have and maintain a firm grasp on the plug as the last thread is turned because it will want to fly upwards under the spring pressure, remove and discard the O-ring fork tube plug o-ring, remove the fork spring from the fork tube, remove the fork assembly from the fork tube holder tool, being aware that the damper valve if one is installed (All touring models, with the exception of Road King, have a damper valve type fork on both the left and right sides. Road King uses the conventional type fork on both sides.) will fall out when the fork tube is inverted for draining turn the fork upside down and drain the fork oil into a suitable drain pan while slowly pumping the fork tube and slider at least ten times and then allow about 10-15 minutes for the fork assembly to completely drain. THEN with the fork tube right-side-up securely clamp the fork slider (not the fork tube) into the fork tube holder, install the drain plug at the bottom of the fork slider, if it had been removed and tighten the plug to 72-96 in-lbs (8-11 Nm).

MODEL FORK TYPE AMOUNT
OZ. ML IN. MM
All models Damper Valve 10.7 317 4.92 125
Except FLHR/C
FLHR/C Conventional 11.0 325 4.92 125

Pour slightly more Harley-Davidson Type E Fork Oil directly into the fork tube than is specified for the fork type, slowly pump the fork tube until some resistance is felt and then pump a few more times and then for all models except FLHR/C (i.e. for damper valve type forks), install a new wear ring in its groove in the damper valve, with the wear ring at the bottom (spring side up) slide the damper valve into the fork tube, install the fork spring into the fork tube, use the fork spring to push the damper valve to the bottom of the fork tube, remove the fork spring from the fork tube, slowly pump the fork tube a few more times to eliminate air from the damper valve, adjust the ring of a fork level gauge 4.92 inches or 125mm and then with the fork tube bottomed in the fork slider insert the tube of the gauge into the fork slider until the metal ring rests flat on the top of the fork tube and use the gauge plunger to draw oil from fork (if no oil is drawn out, add a small amount to the fork tube and repeat the process) until the oil level is at the specified level in the fork slider, install the fork spring into the fork tube with the tighter wound coils at the bottom, remove the fork slider from the fork tube holder tool, clamp fork tube into the fork tube holder tool, install a newO-ring onto the fork tube plug, install the fork tube plug into the fork tube and tighten it to 60-70 ft-lbs (81.4-94.9 Nm), install a newquad ring seal onto the fork cap bolt and install it into the fork tube plug to prevent loss of fork oil while working further with it. THEN on right side fork, loosely install the axle holder with its flat
washers, lockwashers and nuts, install the fork and assemble the motorcycle.

To remove a 2010 Touring 41 mm fork assembly FIRSTraise the front wheel, remove the front wheel, remove the front fender, and for FLHR/C remove the headlamp nacelle. And for FLHX, FLHT/C/U, FLHTK remove inner fairing cap, and for FLTRX remove the instrument nacelle, loosen the fork cap bolt, but do not
remove it at this time, loosen the pinch bolt but do not remove it, hold the fork slider to prevent the fork from dropping, remove the fork cap bolt from the fork tube plug, slide the fork tube down to remove. And loosely install the fork cap bolt to prevent loss of fork oil while working with the fork.

DISASSEMBLY
To disassemble a 2010 Touring 41mm fork assembly FIRST remove the fork assembly, the right side fork remove the axle holder from the end of the fork slider, drain the fork, install the fork spring into the fork tube, place a shop cloth or towel on the floor, turn the fork assembly upside down, press the end of the spring against the shop cloth or towel to prevent rotation of the damper tube and remove the metric screw from the end of the fork slider with an air impact wrench, discard the screw and copper washer, remove the fork spring, the damper valve (if equipped) and the damper tube from the fork tube, remove the wear ring and rebound spring from the damper tube, remove the wear ring from the damper valve, (if equipped), remove the retaining clip using an appropriate pick tool, remove the fork tube from the fork slider by using the fork tube as a slide hammer tool, slide the fork oil seal, the slider spacer and the slider bushing off from the end of the fork tube, discard the fork oil seal and the slider bushing, gently pry at the split line to expand the fork leg bushing and remove it from its groove at the end of the fork tube, discard the fork leg bushing and remove the lower stop from fork the slider.

CLEANING AND INSPECTION
Thoroughly clean and inspect all parts and replace any parts that are corroded, bent, inoperative or otherwise obviously damaged, inspect the fork cap bolt quad ring seal and the fork tube plug o-ring for cuts, tears or signs of deterioration and replace if and as necessary, replace the retaining clip if is bent or distorted, check the slider and the fork leg bushings for scratches or excessive wear and always replace bushings in a set if either bushing needs to be replaced, check both the fork tube and the fork slider for scoring, scratches and excessive or abnormal wear and replace parts if and as required, set the fork tube on V-blocks and measure its runout using a dial indicator gauge and replace it if the runout exceeds 0.008 in. (0.2 mm), inspect the upper fork spring and the rebound spring for damage or distortion, and replace the upper fork spring if its free length is less than19.27 in. (489.4 mm) for Non-Fairing Models and 18.73 in. (475.7 mm) for Fairing Models and replace the rebound spring if its free length is less than 0.938 in. (23.8 mm) or any time the upper fork spring is replaced.

ASSEMBLY
To assemble a 2010 Touring 41 mm fork assembly FIRST coat the ID of the fork leg bushing with clean fork oil, expand the fork leg bushing at the split line only enough to slip it over the end of the fork tube and into its groove on the fork tube, install a newwear ring into the groove at the top of the damper tube, install the rebound spring on the opposite end, with the wear ring topside slide the damper tube into the fork tube so that the tube end drops through the hole at the bottom of the fork tube, install the lower stop at the end of the damper tube, install the fork slider into the fork tube holder tool, slide the fork tube into the fork slider, coat the ID of the slider bushing with clean fork oil, slide the slider bushing down the fork tube, slide a 41 mm fork seal installer tool down the fork tube and using the it as a slide hammer drive the slider bushing into the counterbore of the fork slider, then remove the tool, place masking tape over edge of the fork tube to avoid damaging the lip of the fork oil seal during installation, coat the ID ofa new fork oil seal with clean new fork oil, then with the lip garter spring side facing down toward the fork slider slide the seal down the fork tube until it contacts the slider spacer, remove the masking tape from the edge of the fork tube and using the 41 mm fork seal installer tool as a slide hammer, drive the fork oil seal down the fork tube until the retaining clip groove is visible above the seal in the ID of the fork slider, remove the tool, install the retaining clip in the groove, install the fork spring into fork the fork tube, remove the fork assembly from the fork tube holder tool, place a shop cloth or towel on the floor, turn the fork assembly upside down and press the end of the spring against the shop cloth or towel to prevent rotation of the damper tube, install a new screw and a new copper washer at the bottom of the fork slider and while compressing the spring tighten the screw to 132-216 in lbs(14.9-24.4 Nm), remove the fork spring from the fork tube, fill the fork with fork oil to the specified amount and complete assembly of the fork. On the right side fork, loosely install the axle holder with its flat
washers, lockwashers and nuts.

INSTALLATION
To install a 2010 Touring 41 mm fork assembly FIRST remove the fork cap bolt, slide the fork tube up and into the slider cover, lower the fork bracket, the fork stop, and the upper fork bracket, install the fork cap bolt, install the pinch bolt and lockwasher into the lower fork bracket and tighten the pinch bolt to 53-57 ft-lbs(71.9-77.3 Nm), tighten the fork cap bolt to 60-70 ft-lbs (81.4-94.9 Nm) and repeat these steps on the other fork, install the front fender and wheel, and for FLHR/C install the headlamp nacelle, for FLHX, FLHT/C/U, FLHTK install the fairing inner cap and for FLTRX install the instrument nacelle.

May 15, 2014 | 2010 Harley Davidson FLHX Street Glide

1 Answer

2007 Harley Davidson FXSTB. Changing fork oil and have misplaced my manual. How much fork oil do I put in the tubes after all drained ? Appreciate your help!


I'm sorry but I don't have that information on the newer bikes. I specialize in the older bikes that the dealers will no long work on. You can call the service department of any local dealer and they should tell you how much oil goes in it. Ask for the "wet" quantity. This is the amount of oil you add when you simply drain and refill the fork tubes. If you disassemble the fork tubes, you need to add the "dry" quantity of oil.

Good Luck
Steve

Aug 27, 2011 | Harley Davidson FXSTB Night Train...

1 Answer

My 2002 fxd front forks are soft and come close to bottoming out. Does the fluid need to be changed? if so how and how much?


Yes your fluid may need to be changed if you want a more firm front end. I don't know what type of fluid you have in the forks now but what you need to do is to go with a thicker oil. In my '94 FXDWG, I went to PJ1 30 weight oil. Since I don't have a book on your late model bike, I can't tell you how much oil to put into each tube. There is a "wet" and a "dry" quantity to add when you've drained them. If you simply drain the oil and refill the fork tubes, use the "wet" quantity of oil. If you disassemble and clean the tubes out, use the "dry" quantity when you refill.

To drain the oil, look on the trailing side of the fork sliders. You'll see a screw or a set screw in the slider. Take this plug out and some of the oil will simply flow out. To get all of it out, hold the front brake and push down on the handlebars. Now, oil will spray everywhere so don't do this job in your living room. Once you get the oil out of both tubes, reinstall the plugs and refill the tubes one at the time by removing the top cap out of the tube and pouring the prescribed amount of oil into each fork tube. Ride the bike and see if the front suspension is too soft, too firm, or just right. Remember, the heavier the viscosity of the oil, the more firm the front suspension is. If you can't get it right, you might want to consider changing the springs in the fork tubes.

Good Luck
Steve

May 04, 2011 | 2002 Harley Davidson FXD Dyna Super Glide

1 Answer

Switching lower for sliders out to chrome need instructions to assemble and disassemble


There are two ways to change out the lower sliders on your bike. One, remove the entire fork tube from the steering head and the other, simply remove and replace the lower slider. There really isn't that much difference and I prefer to remove the entire fork tube myself.

First you'll have to get your bike off the gound and stable. Then remove the front wheel, the front brake and the front fender. Remove the windshield, light bar, and nachelle.

Once you get everything out of the way, here's where you can go two different routes. In one, you loosen the clamp bolt at the lower triple tree and remove the top cap of the fork. Spray a bit of penetrating oil around the fork tube in the lower tree and start working the tube out. Once the tube is out, remove the top plug and spring. Turn the fork tube upside down and empty the oil out of it and remove the spring. Look at the spring. It's tapered on one end, make sure you put this end in first when you reassemble the tube. With the fork tube upside down, look at the bottom end of the slider where the axle goes through. You'll see a single 8mm bolt. Remove this bolt and the slider will come off.

In the other method, you do it the same way except you don't remove the fork tube from the triple. You remove the top cap and the tube plug. Remove the drain plug and drain the oil out of the fork tube. Remove the screw and remove the lower slider. It is quite a bit messier as all the oil is not out of the slider when you take it off.

When you reassemble, make sure you use the proper quantity of oil in each leg. You will see a "wet" and "dry" measurement. Use the "dry" measurement since you disassembled the fork. I do not have the quantity of oil you should use for your model. A dealer should be able to tell you.

Good Luck
Steve

Nov 14, 2010 | 2005 Harley Davidson FLSTC - FLSTCI...

1 Answer

Fork seal replacement


If all you want to do it replace your fork seals, if you can find a way to jack the bike high enough, you don't have the fork tubes our ot the triple trees. Work with on fork tube at a time. Raise the bike up off the ground and take the front wheel and fender off. Brake caliper off it's tube. Now raise the bike up to where you've got about a foot of clearance below the lowest point of the slider. Look underneath the slider where the axle goes through and you'll see an 8mm bolt. Take this bolt out and your lower slider will come off. The fork oil will start to drain as soon as you take the bolt loose as well. Leave a pan under the upper fork while you work on the lower to catch the dripping oil. Replace the fork seal and reassemble that tube. Then, do the next one. Now, refill the tube with the correct amount of the correct oil from the top by removing the top cap nut. Pour in the correct amount of oil for a "wet" refill. The thicker the viscosity of the oil, the firmer the front fork action. I think they came with H-D type E which seems to be a bit softer action than 30 weight fork oil. Make sure you use fork oil. Regular engine oil or transmission oil should not be used and it will foam if you're riding down a rough road and your forks will collapse and not work until the oil settles again. Not a pleasant feeling. It's really doubtful if you'll get anywhere that is that rough with your Harley.

Good Luck
Steve

Sep 12, 2010 | 1993 Harley Davidson FXR Super Glide

3 Answers

How do i drain the fork oil on my 2005 dyna fxd


There should be a drain plug on the trailing side of the slider. Some have cross point screwdriver heads on the plug others have allen or hex head plugs. Remove the plug and work the forks up and down. If all fails, you can remove the entire tube and turn it upside down.

Apr 22, 2010 | 2005 Harley Davidson FXDL - FXDLI Dyna Low...

2 Answers

How do you replace fork oil and what do you do with air valves on 1981 kawasaki kz650 csr front forks? Do you pour in new fork oil and then insert air through the air nozzle on each individual front fork?...


Your owners manual will help if you have one. There used to be drain plugs under each fork. The air valves help suspension smoothen the rides more.

Oct 17, 2009 | 1981 kawasaki Z 650 SR

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