Question about kawasaki VN 800 A Vulcan Motorcycles

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I need instruction for putting new seals and adding oil to front forks.

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Forks are of many types, you should get a maintenace manual for your bike as it is a job only for the informed.

Posted on Aug 23, 2010

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1 Answer

Blow-by of the left front fork 'seal' (Honda M/C 1981 cm400c)\r\nI also own 1980 (same) but it doesn't have the 'air' added on top like this '81. . . 1) question: ` Could I just drain the fork oil...


Probably the reason the fork seal is blown is too much air pressure. Definitely fix the seal and put in the correct amount of oil. You do not have to put air in to the front forks if you do not want to. To properly set up your suspension, set your rear shocks first, hard for two, soft for one, etc. Now load the bike, you or you and the passenger. With the front forks set to near max pressure (only 12 to 14 pounds air pressure do not go over max recommended pressure) bounce on the motorcycle seat and bleed off the pressure in the front forks till the front and back of the bike drop together. This is the correct way to set up your suspension. A bicycle foot pump with a pressure gauge works best works best. You will be near max pressure in one small hand squeeze of the foot pump. You will find it only takes 7-8 pounds of pressure to set up your bike. Just remember, You do not have to put air pressure in to your front forks, they will work just fine. You just wont benefit from the adjustable design.

Sep 09, 2010 | 2002 Buell M2 Cyclone

1 Answer

How do u fill the down tubes on a hoda shadow


First of all do not add oil to your front forks with out draining them first. If you over fill your forks with oil you will damage your forks. To change your oil in your forks, first center stand the bike and lift the front wheel by putting a jack under the motor. Remove the front wheel and axle and put a pie tin under the fork tube. Reach up into the bottom of the fork tube with a hex key and loosen the screw but do not remove. Now take the air pressure cross over tube off, this will allow you to unscrew the fork tops( On some bikes you may have to put a towel on the tank and unbolt the handle bars to get them out of the way.). Pull the screws out of the bottom of the forks and gently pull down the oil should come out now. If you need new fork seals take the lower tubes off and replace(You may need to take off the fender and hang the calipers with wires.). Turn the lowers over and dump out the oil and reinstall fork lowers. Snug up screws and sealing washers on the bottom of forks you can not tighten till you put on fork tops. Now pour in measured amount of oil, again do not over fill. Put on fork tops and air crossover tube. Now tighten screws on bottom of fork. Finish reassembling bike.

Jul 14, 2010 | 1989 Honda VT 1100 C Shadow

1 Answer

94 shadow vt1100 front forks to soft.


Does it have a bad fork seal? Check this by popping the dust cover off the lower legs and if you see fork oil on top of the seal than it has gone dad and needs replaced. Adding oil to the forks will stiffen then back up but if you have bad seals then you will be adding more oil again in a very short time and also this is dangerous cause the oil can get on the brake pads and cause brake fade when you need them.
Good luck.

Oct 17, 2009 | 2003 Honda Cb 400 Super Four

1 Answer

Can you tell me how much oil to put in an en500 forks please, Andy


If you never have put for oil into a set of forks, yes you have to check both forks. I would suggest treading lightly. If you have time and a place to block the bike as well as a manual you can do it.
Are you adding oil because the seals are leaking or do you have excessive stiction in the fork? If the seals are leaking, you will have to pull the forks and add new seal and put in exactly the right amount oil.
Do you have air seat or is it a closed fork?
For you en500 you should have a volume of oil in your service manual.

Aug 17, 2009 | 2005 kawasaki EN 500 Vulcan

3 Answers

How do I change the fork seals on a 2008 Honda CRF 250 r? Do I use a special tool? Oil? How much oil? Thanks so much for your expertise. Do I put equal amounts of oil on each side? Inner tube- outer tube?


hi,replacing the seal is quite easy,although it will sound complicated,jack up or lift the bike off the ground so that the front wheel is in the air(about 12-14 inches should be enough,remove the front wheel from the bike,remove each fork leg,this is done by undoing the bolts(4 on each leg)the front fork is quite easy to work on just do one at a time,remove the dust cover from the top of the staunchion tube(larger diameter tube),beneath that dust cover you should see a retaining clip that holds the seal in place,remove the retaining clip(and dont lose it),the seal is now ready to remove,the easiest way that i know to do this is to force a screwdriver through the body of the seal,you may need to hit the screwdriver with a hammer as some seal have a tin backing plate,put a hole through the seal on each side of the fork leg taking care not to damage the chrome of the fork leg,then use the screwdriver to lever the seal out of the fork leg,to reinstall the new seal,put a smear of grease or oil around the outside of the new seal,slide the new seal down the fork leg and seat it squarely into the fork tube,very carefully tap the new seal into place being very carefull not to damage the outer surface,i use a small piece of dowell type timber to do this as the wood doesnt damage the seal surface,i use a small ballpeen hammer to tap the wooden dowell,once you have the seal seated down the tube you should be able to see the groove for the retaining clip,reinstall the retaining clip making sure it is seated corectly,replace the dust cover,if you are going to replce the fork oil or top it up do this once the fork leg is back in the bike,repeat the whole procedure for the other fork leg,once you have done the fork seals reinslall the fork legs back into the bike and refit the front wheel,to top up the oil in each leg,simply undo the large cap on the end of the fork leg,you may have to remove the handlebars to do this,be carefull as the cap will be spring loaded and can easily fly off if you are not ready for it,top up or fill with the correct weight oil for your bike(normally a 10w oil),check with your local honda agent for the correct quantity,normally between 400-500 mls,this all sounds quite complicated but is actually quite easy and can be done with a minimal of tools,each fork shold take about 1/2 hr to do...hope this is a help to you

Jul 15, 2009 | 2005 Honda CRF 250 R

1 Answer

Seals blown on front shocks


to remove seals you will need to remove each fork leg from the bike,i put the bike on the centre stand and jack under the motor to get the front wheel off the ground,after you remove the fork leg,remove the dust cover(if fitted),remove the circlip holding the old seal,you may have to stab through the old seal with a screwdriver to remove the seal from inside the leg(be carefull not to damage the chrome on the fork leg),clean around the surfaces and install the new seal making sure it goes back in dead square,refit the circlip,then refit the dust cover,replace fork tube back in bike and top up with new oil,most bikes take between 300 to 500cc of oil,but check with your local shop as all bikes are different,and you can adjust the amount of rebound damping by varying the amount of oil you put back in,..sounds complicated but quite an easy job..hope this helps

Jul 04, 2009 | 1995 Suzuki GS 500 E

1 Answer

Hi my name is Andy i have a GS550 cafe racer the falk seals are leeking how much iol do you need per leg? andy.williams@hotmail.co.uk


you should put in new fork seals before adding oil -leaking fork seals should be repaired as oil can get on the front brake pads--buy a clymer manual and you can change them yourself

Jun 26, 2009 | 1983 Suzuki Gs 550 L

1 Answer

Front fork leaking oil from bottom of the seal.


change the oil seals and oil in the fork,and avoid wheelies on the bike and off road biking 

May 17, 2009 | 2004 Honda CRF 250 R

1 Answer

How do i dismantle front forks to replace the oil seals


You just needed to.... remove front wheel, support bike on something, undo retaining bolts on forks, tap out fork legs from the top, using a soft mallet. Take out fork seals with a seal pick, (halfords) Replace old seal with new seals, in reverse order) sliding over the fork leg, tapping into place. Then put replace forks etc in reverse order (from dissassembly). Hope this helps

Feb 21, 2009 | 1992 Honda CB 750F2 Seven Fifty

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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