Word of warning when changing fork oil - Suzuki Volusia Forums : Intruder Volusia and Boulevard Forum
 
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post #1 of 5 (permalink) Old 06-01-2019, 01:42 PM Thread Starter
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Word of warning when changing fork oil

I did this task today. What I thought would be simple turned into an afternoon of sweating, cursing and sore hands.
Jacked the front end up, wheel off the ground.
Top caps came off nicely, with a towel wrapped around so it didnt shoot into the ceiling.
Swapped out the oil, then went to reassemble.

I think they changed the design at some point, because i've read posts where people claim you undo the top cap, then there is a large allen bolt keeping the spring compressed. Well on my 05 bike that was not the case. The spring seats against the rim of the top cap. On removal you have 2 to 3 inches of spring sticking out. The thread on the cap is very fine and quite soft.
So what you have to do is somehow push the cap down with enough force, while not allowing the cap to slide off (because the spring doesn't even seat INSIDE the cap, only the edge) then line up perfectly and start bolting it up.

Really its a 2 man job, its barely possible on your own. Even with 2 people it took a few goes. Absolutely awful design though, it would be so much easier if the spring sat inside the cap to give more control but it doesnt. Add to that the fact that the threads are picky, you have to have the cap perfectly centered and perfectly flat.

That said it was well worth doing, the bike no longer nose dives at any given opportunity and cornering feels a lot nicer. It had about 150ml of old oil each, so it was well low
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post #2 of 5 (permalink) Old 06-01-2019, 02:12 PM
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Sounds like a riot!
You're welcome to do mine anytime you like!

Someone needs to invent the oil dissolving zip tie.

“Society is nothing more than people cooperating with other people they'd much rather murder.”


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post #3 of 5 (permalink) Old 06-01-2019, 02:15 PM Thread Starter
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Originally Posted by bbqjoe View Post
Sounds like a riot!
You're welcome to do mine anytime you like!

Someone needs to invent the oil dissolving zip tie.

I'm confused because in some manuals it states there is a spring stopper bolt under the topcap with an allen head, and a rod going down the centre of the spring. Mine had none of that, its just the topcap that holds the spring under tension. Maybe its a UK thing or someone previously has messed with the forks and never put it back, though it seems unlikely
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post #4 of 5 (permalink) Old 06-01-2019, 03:12 PM
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Quote:
Originally Posted by EazyDyz View Post
I'm confused because in some manuals it states there is a spring stopper bolt under the topcap with an allen head, and a rod going down the centre of the spring. Mine had none of that, its just the topcap that holds the spring under tension. Maybe its a UK thing or someone previously has messed with the forks and never put it back, though it seems unlikely
Not a clue.
I've never pulled mine apart.

From what I gather here, these front ends aren't worth a flyin' whozit.
Frankly I'm kinda surprised they even come apart.

“Society is nothing more than people cooperating with other people they'd much rather murder.”


2009 C-50T
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2 Jack Russell's
And a Les Paul

Last edited by bbqjoe; 06-01-2019 at 03:14 PM.
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post #5 of 5 (permalink) Old 06-01-2019, 04:38 PM Thread Starter
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Originally Posted by bbqjoe View Post
Not a clue.
I've never pulled mine apart.

From what I gather here, these front ends aren't worth a flyin' whozit.
Frankly I'm kinda surprised they even come apart.
Well I can tell you one thing, the bike handles much better now. It got so bad before that if I was braking from 30mph toward a red light, the entire front end would compress what felt like too much. Not anymore, its a lot firmer, speed bumps are a bit more brutal but its a fair trade off. I used 412ml of Castrol 10w synthetic fork oil.

Its not like this anymore

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