How to change fork oil in 81 550L

[jimfj]

I have changed, added, expirimented with fork oil in several bikes before toying withthis one. I have always had access to filling the forks from the top with no problem. This 550L has two rubber caps on the top of each leg that come off to reveal no way to get to the springs/oil inside.

Has anyone found a way to get the fork oil in without removing the forks from the bike? The forks have drain screws on each leg. I browsed a manual on Cliff's website but didn't glean much from it other than the capacities ect. What i'm looking for is tips on the process.

This a friends first GS and he's just learning to ride. We are replacing the front tire and trying to lessen the front end dive and we'll probably add some spacers or cut the springs to stiffen the front up a bit.

Any help/comments appreciated.

Jim

[Hammered]

Im gonna keep an eye on this one. Im just rebuilding my first set.

[hampshirehog]

To get it right I really would suggest removing the forks from the bike. However, once you've done it the first time you can make your own measurements to the level of the fork oil (at an angle, forks fully extended etc rather than vertical, forks fully compressed as per the manual).

I'm not familiar with the US L model but I'd bet the fork tops are the same as the ones we got. Basically you pull off the black plastic caps and then push the disc in the top of the fork tube down (big screwdriver or socket extension is ideal) - you should see a circlip (spring clip in your language I believe). Hook this out with a small screwdriver -cover the top with a rag while you do it so that the thing doesn't fly off never to be found again. Sometime the disc will fly off (take care) and sometimes they jam in a bit and have to be worked out.

Refitting is the reverse procedure.

[hampshirehog]

My manual gives the fork oil level for a US 81 550L as 208mm by the way. Forks upright, springs removed, measured from upper end to top of the oil.

[jimfj]

You are all gentlemen and scholars!

If I am understanding this right, there is a metal cap that can be pushed down?

I see what you are speaking of and it has a sort of indentation in the center. I understand your method using the socket extension which I have. Do I need to loosen the clamps holding the fork tubes or leave them alone?

I appreciate the advice!

[hampshirehog]

Once you push down on that cap and ping out the clip the springs will come out the top and your forks will collapse i.e. your handlebars will move down as if your pushing down very, very hard. Therefor either remove the forks from the bike first or make sure that the front end is fully supported to stop it making a nosedive for the floor.

That cap with the indentation is the cap you need to push down to enable you to remove the clip. (The indentation helps stop your socket bar from moving around).

[jimfj]

I have it now, thanks for the help.

I greatly appreciate your time.

Just a note:

This kind of thing is what makes this forum such a wonderful tool. I have about 5-6 friends that have GS's and we all have learned from this site. Everyonce in a while we get stumped or just want to do something one time and everyone here comes through.

Thanks again.

Jim

[twr1776]

The one time I worked on that type of fork the clip went flying when I popped it out. Maybe have someone near by to see where it flies or hold a rag over the top of the fork.

[chef1366]

Instead of trying to get the clip out first put a impact gun on the bottom of the forks and take out the bottom fork bolt. The inner fork won't spin with the spring in.
Change the seals and clean it all up while in there.