Question about 1993 Honda XR 250 R

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How to get fork caps off 1993xr250r to change oil

Loosened caps on top of fork but hey feel anchored to something

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  • Dave Beon
    Dave Beon Nov 30, 2014

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Be careful with them they are under pressure from the springs make sure to lift the front off the ground, or remove forks from the bike. If the forms are upside down type when you open the top nut the outer leg should slide down allowing access to oil.

Posted on Dec 03, 2014

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Posted on Jan 02, 2017

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1 Answer

When determining oil capacity and air gap in forks is there a "universal" starting point. I tend to rebuild older bikes and often there is no or little info available.


Hey Anon.. Yes, there is a positive/accurate way to tell how much oil is required,...on older bikes with "standard" forks all the dampening controls are on a rod secured to the bottom of the fork leg. If you remove the filler cap (top), with NO oil in the fork, you can see the top of the rod (its in the center of the fork tube towards the bottom). When refilling, the oil level must be enough, with fork fully extended, to just cover the top of the dampening rod...add about 1oz of oil at a time ..look down with a flashlight.. until the rod is covered!1 This is a slow, but accurate, way to fill older forks!!

Jun 15, 2017 | Motorcycles

1 Answer

How do I refill my fork tubes with fork oil


Begin by loosening the upper triple-clamp pinch bolts and breaking the fork caps loose while the fork is still held by the lower triple clamp. You will need to remove the caps to refill the fork tubes with oil.
Determine if the fork legs have oil drain plugs near the bottom of the legs. If they do, you are in luck and will be able to change the oil without removing the fork legs. Put old newspapers on the floor under the front end. Place a drain pan under the fork legs and remove the drain plugs, one side at a time. Hold the front brake and push down on the fork several times to pump the oil out. When oil stops coming out, reinstall the plugs using new sealing washers.
Without Drain Plugs
If there are no drain plugs (look carefully), you'll need to remove the fork legs to drain the oil. At this point you can decide to have it done professionally or do the work yourself. We'll cover the main, basic steps. Refer to a shop manual to learn all the exact procedures involved. Some motorcycles may require fairings, handlebars, etc. to be removed.
Support the motorcycle either on the centerstand (if equipped) or by using a motorcycle jack under the engine. If you use the centerstand, you may need to place a sandbag on the rear of the seat, hold the front end up using straps from the rafters, or support the bike underneath the engine. Use tie-downs to steady the bike on the jack. Grasp the lower fork legs and try to push and pull the fork toward the back of the bike and forward to check for loose steering head bearings. Inspect the pleated rubber fork boots, if equipped. Check for signs of fork oil leakage and any grooves in the fork tube wear surfaces where the seals make contact. Also check for looseness between the fork legs and tubes that would indicate bushing wear.
Remove the front wheel and axle assembly. Support and tie the brake caliper(s) out of the way. Remove the front fender and speedometer cable, if equipped. With the fork leg fully extended, remove the top cap from a leg. Be prepared as there may be some spring pressure pushing against the cap.
Loosen and remove the pinch bolt from the lower triple clamp and lower the fork leg. Note any shims or washers and spring. Turn the leg upside down in a drain pan until oil stops flowing out. You may have to move the damping rod in and out to get the oil out. Repeat the procedure for the other side.
Reinstall the fork legs and other removed components in the reverse order of removal.
All Models
Add the exact amount and type of oil recommended by the manufacturer. Some motorcycles call for the use of a dipstick to determine how much oil to use instead of just pouring a certain amount of oil back in. Follow the manufacturer's shop manual recommendations.
Carefully install the threaded top caps by hand to avoid cross-threading. Tighten the pinch bolts and top caps to the factory-specified torques. After the brakes are installed, pump up the lever until the brakes feel normal again. Once the bike is assembled and on the floor, push down on the front end to verify the suspension's response. Turn the steering from its left to right limits to ensure nothing is binding, and check all controls including the throttle for proper operation.

Mar 05, 2016 | Motorcycles

1 Answer

Changing fork oil


Remove forks from bike, with each fork remove end cap and drain plug over a bucket drain oil from each fork reinstall drain plug on lower leg, replace oil thought top of the fork to spec, replace end caps and bleed oil from forks

Apr 18, 2014 | 2004 KTM 50 Adventure Senior

1 Answer

2003 HD sportster - forks don't leak, bottoms out when front brakes applied


You may not have enough oil in the front forks or you may been a heavier viscosity of oil. I'm sorry but I don't have the oil capacity for your "Low Sportster". All I have is for "Hugger" models. They take 10.7oz. "wet" and 12.1 "dry". The difference between "wet" and "dry" is that if you simply drain and refill the front forks, it's call a "wet" oil change. If you disassemble and clean the forks of all oil inside, it's called a "dry" oil change. Contact the service department of your local shop and ask them how much oil goes in the front fork. To change the oil, there is usually a small screw in the trailing side of the lower fork slider down near the axle. Take these out and the oil will drain to a certain degree. Hold the brake while working the forks up and down with your weight to get all the oil that draining will get out of them. If you want all the oil out, you'll have to disassemble the fork tube. I would not do this if the seals are not leaking. Replace the screws in the sliders and then remove the top cap from one tube at the time and refill the tube with the specified amount of oil. Sometimes, the top caps can be difficult to get back in due to the pressure of the large spring in the front fork tubes. You may need a tool to compress the sping. I'm not sure on the "Low" model. I've always managed to the top caps back in without any special tool but I've never done a "Low" model bike. Harley uses what they call their "Type E" fork oil. I do not know what the viscosity of this oil is so I always use PJ-1 30 weight fork oil for most applications. Use only fork oil as any other oil may have a tendency to foam thereby negating any dampening action of the forks. If this doesn't solve your problem, you may want to check into changing the springs in the front forks. Progressive Suspension and others make kits for this.

Good Luck
Steve

Sep 13, 2011 | 2006 Harley Davidson XL 1200 L Sporster...

1 Answer

How do i change the oil seal of the front suspension of my kawasaki 1994 zxr 750?


You need prop the bike up on front and rear stands. The fron stand needs to be the type that holds the bike up by the headtube. Remove brake calipers, front wheel, fender. Then loosen the upper and lower triple clamps. Loosen the clip ons. But before loosening the lower triple, loosen the fork tube top caps.

Drop out the legs. take off the top caps, pour out the oild, and compress the spring. I'd use a fork compressor, race tech makes a nice one. Loosen the top cap from the damping rod. Remove the top cap then pump out the rest of the oil from the damper.

Next, remove the outer dust seal. Remove circlip. Then you need to just extend the fork several times quickly to "bang" out the oil seal and bushings.

The outer bushings, if they look good, need to be gently pryed off using a thin flat head screw driver in the **** of the bushing. Same with the inner bushing. Now the oil seal, metal washer and circlip all come out together. Remember the order.

Lube up the new seals with fresh oil. put back on the fork lowers in the same order they were taken off. Replace bushings at the same time if there's any brass showing. I usually do it any way since the seals seem to go at the same rate as the bushings for me.

Once back together, seat the seals. There's a tool for this, but I usually **** the old oil seal so I can get it on the lower fork tube between the new oil seal and new dust seal. and I quickly compress (bang) the fork a few times until the groove on the upper leg is showing so the circlip will lock back on. Probably not recommended but I haven't ruined a dust seal in about 20 years now.

Fill fork with proper oil viscosity and volume (don't remember how much or weight for zx7s). cycle the damper about 20 times to make sure they're full of oil too. insert spring, re-compress, lock on top cap to damping rod. screw on top cap. reassemble fork on bike. Remember to torque the top cap with the top triple clamp loose otherwise the caps can bind.

Mar 22, 2011 | 1994 kawasaki ZXR 750

1 Answer

Changing oil in forks


lower for legs there should be a drain bolt for each leg do one side at a time.
Take the top fork cap off be careful the top cap is spring loaded get a pan to catch the oil,remove the drain bolt let it drain.reolace the drain bolt then you can add your new fork oil,check your owners manual for the proper amount and weight oil you need to replace, replace the fork cap.
repeat steps on the other fork.

May 09, 2010 | 1983 Honda XL 125 R

2 Answers

Change oil fork


There is a bit of directions on how to change the oil. I will give you a link to a site that has pictures with step-by-step directions that will work for any bike fork.

http://www.bluepoof.com/motorcycles/howto/svs_fork_oil/

If you have any more questions, feel free to ask..

Nov 25, 2009 | 2004 KTM EXC 200

1 Answer

Steering problem


Sounds like you hit a pot hole and have a slight bend in one of the forks. Alternate to that, pull the caps on the forks and be sure the oil level is the same in both forks. The oil should be 3 to 5 inches from the top of the fork.

Apr 26, 2009 | 2005 Suzuki GSX 750 F (Katana)

1 Answer

Changing Fork oi on 91 FLH


each fork takes 11.5 ounces of folk oil, and for a 91, use heavy duty fork oil, they fill from the fork tube caps, remove them from the top of each fork, support the bike so the front wheel is off the ground, tighten the Caps to 40 -60 lbs when yer done

Mar 09, 2009 | 2000 Harley Davidson FLHTCUI Electra Glide...

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

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