Fork maintenance?

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May 10, 2013
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Roatan, Bay Islands, Honduras
Thanks. 22,000 mi. on my 2014 base model Tenere. Should I be wanting to change out tho front fork oil now? Seals too, I guess? I ride easy and no oil leaks....knock on wood. How about that mono- shock in the rear....any maint. required? It runs like new....and rides comfortably....2 up. Had full lube done, plugs, battery, coolant, oil, air filter. etc. done six months ago, but forgot about the forks. If I need a kit, could someone please post a link for me? Thanks. I live out of the country and my dealership changed hands and now won’t order any parts. No problem....I just have to ship it in via my freight forwarder. . Thanks a lot...mucho appreciated!
Regards, Scott Williams, Roatan
 
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jrusell

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Forks are over due for new oil. If seals are not leaking there is no need for new seals. Pick up 1 liter of 5 wt oil and do it yourself in a couple of hours.
Shock is not serviceable in it's current form, so leave it alone.
 

bnschroder

2014 Super Tenere ES
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What happens if you don’t change your fork oil? I am in the same boat - 2014ES, 25,000 Miles, no plans of changing the fork oil.


Sent from my iPhone using Tapatalk
 

jrusell

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Fork springs are constantly rubbing on interior of fork leg creating tiny metallic particles floating in the oil. This will cause wear to bushings, chrome tubes and all interior parts of the fork. These particles settle in the bottom of the fork and clog valving. Frequent changing of the oil removes these particles and keeps the fork performing as it was designed to do.

Over time fork oil breaks down losing it's viscosity and looks like a dirty watery mixture. Left long enough you will find a nice metallic paste in the bottom of the fork. This will require a complete tear down and much higher cost than if you change your oil frequently and keep it in good condition.

It is always preferred to do a complete disassembly to get everything perfectly clean, but I realize most don't have the tools or experience to do this themselves. A simple dump and fill every so often will keep it in good condition, working well ,requires no specialty tools and only a litre of oil.

Personally I change fork oil every year. Maybe more often depending on mileage and if I want to try a lighter or heavier oil. My tenere had 4500km on it when I picked it up last year and I did the fork oil almost immediately.
The oil was not terrible but there was considerable metallic particles in the oil. 25,000 mile fork oil will be a nasty black mess.

New oil
DSC00655.JPGDSC00652.JPG
4500 Km factory fill
 

ace50

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Wow, do you replace the brake lines every two years like the manual suggests too?
 

jrusell

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I was expecting some to think this is excessive.

Hey it's your bike. Do whatever level of maintenance you desire, but the fact is suspension is the most important part of your bike and the least maintained.

People spend thousands on Farkles but are unwilling to spend $15 on a bottle of fork oil and a couple of hours working on therir bike one time per year to keep it in top condition.

Every week we get posts from people with issues/failures that would never have happened if they had done regular maintenance such as brake flushes, cycling abs, fork oil changes etc.
The attitude of ride it till it breaks and then bitch about it is all too common.
Props to the original poster who is obviously looking maintain his ride.

Maintain your bike or don't. It doesn't really matter to me.
And no I don't replace lines every 2 years.
 
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Ramseybella

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So without experience or a bunch of contraptions to keep things off the floor.
How is this simple dump and fill done?
I had Yamaha replace my fork seals and fluid a few months back at almost 80k on the dash and it cost me almost $400.00.
Bushing had some wear but still within specs so we left them in..
 

jrusell

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Pricy, but if you took them your bike and they had to spend time removing the forks from the bike as well the price is probably not far off.
I checked pricing from two suspension shops I have used in the past and they were both around $210-240 for complete service not including parts.(Canadian dollars) But this is you taking forks off bike. If I was going to pay someone I would send my stuff to a reputable suspension shop not a dealer. Preferably a shop who's primary work is on road race bikes. They will be quicker and you will know they are doing a full strip and refresh for a better price than a dealer who is likely just doing a dump and fill. Nothing wrong with a dump and fill, but I don't expect to pay the same as a full service.

Put bike on centre stand and find a way to get the front wheel off the ground. A tie down to a rafter in the garage will work or a block of wood under the engine. I have used a step ladder over the bike with a couple of tie downs attached to the handlebars in the past, but I now have a triple clamp stand which makes the job very easy. Whatever works.
Make note of your compression and rebound clicker settings so you can put them back when we are done, then turn both to fully open position.(counter clockwise)
Remove wheel, brakes and then loosen top triple clamp bolts only. (lower triple clamp still tight.) Make note of fork height in the triple so you put it back to same height when you reinstall. The seam where the cap meets the fork is usually level with the top of the triple.
Using socket, cresent wrench or adjustable wrench loosen fork cap. You may want to put a rag over the nut if you are anal about possible scratches.

After cap is loose,(1/2 turn) loosen the lower triple bolts and remove the forks from the bike.
Get a clean container to collect the used oil and something to accurately measure the volume of the oil you remove. I usually use a white ice cream container and then transfer oil to a ratio rite or other calibrated container to measure the volume. This can get messy so take it slow and try not to lose any oil. If you are doing a dump and fill you will probably put back what you remove so volume is important. I like to setup the container such that I can hang my forks over them to allow them to drain for a long period of time.
A bungee cord through the axle hole to a nail above my bench is what I do. That way I can walk away and let it drip.

The better method to determining oil volume is to set the oil height in the fork, but this requires removing the cap. This requires having a fork compressor. They can be made easy enough, but this discussion is about a quick easy way to service your forks with minimal tools so I won't go there.

Holding the fork vertical loosen the cap fully. You will feel a slight click when the threads are fully off. Pull gold outer fork tube down a couple of inches to expose the inner workings. Turn upside down over your container. Let it drain a while, cycle the gold outer up and down a few times to help expel the oil that is between the inner and outer tubes. Hanging from ceiling makes this easy.
After it has stopped turn forks right side up and place bottom of fork on the ground. There will still be oil in the cartridge, so now you are going to try and get this out. With both hands push down on forks firmly and try to compress forks as much as possible. Do this 3-4 times. Pumping the forks will push the remaining oil in the cartridge to the outer chamber and then it can be removed by dumping into your container.
Invert fork and hang over your container again.
Repeat this 3 or 4 times until you are no longer getting any more oil out of forks. Cycle the gold outer up and down a few times each as well.
Your forks now empty. There will be still a little oil in the forks so the longer they hang the more you can get out. Sometimes I hand mine overnight if I am not busy.
Measure the amount of oil you have removed. I always measure each fork separately. Compare to factory spec, compare one fork to the other as well. Hopefully both of your forks are similar in volume and close to the factory spec.
Factory spec is 150mm oil height, volume 485ml/fork. It is perfectly fine to run slightly more or less oil than spec. More height(more oil) will decrease air gap and create a bit more air spring when nearing full compression.

When I did mine last each of the forks had 450ml of oil. Assuming there was probably a few ml still in the forks and I probably spilled a bit they were not too far off spec. I decided I would go with 465ml .

My fork oil was not very dirty. If it was I would have removed the cap and did a full strip and then set my oil by height not volume, but for this time I felt a dump and fill was sufficient.

Turn fork right side up and pull gold outer up to approx 4 inches from the cap. Lean the fork 20-45 degrees and slowly pour the measured amount of oil back into the fork. I find by leaning the fork slightly I can pour the oil on the fork spring and it is less likely to drip all over the outer tube. Go slow.
When all the oil is in put the fork on the ground. Do not screw cap to the gold outer just yet. Slowly pump the fork cap up/down. The cartridge is still full of air and we need to get it out. This is where having the comp/rebound adjusters open fully helps in bleeding the air out of the fork. You will feel the fork has no resistance to compression at first. After a few pumps it will start to develop resistance as the air is removed and oil takes it's place. You will know when you are done. Usually 10-20 slow full strokes will remove all the air. At this point pull the gold outer up and screw the cap back onto the tube. I like to put a small amount of grease on the threads and the o-ring on the cap. Hand tighten.

Again pump fork hard several times it should feel firm with no gaps in damping. Even if there was air left in the cartridge it will come out quickly.

Put fork back on machine setting fork height like it was before. Tighten/torque lower triple clamp then tighten the fork cap fully. It only needs to be snug. There is no reason to over tighten the cap, the o-ring seals the fork. After cap is snug go ahead and tighten the upper triple clamp bolts.

Reset your comp/rebound settings and you are done.
 
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Commuter Boy

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Halifax NS
Very nice. It would be helpful for the nay sayers if someone posts up pictures of 25,000 km oil to show how foul it gets. I'm always a little astounded at how a sealed environment like inside a fork tube can have fluid and bits break down so much in a relatively short period of time.

The only thing I'd add is that I dump out the oil, measure it, then put in some clean oil, cycle it through, and drain it out to get some extra crud out without a full strip down. Then I add the measured quanitty of new oil in.
 

Ramseybella

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So according to the short version pour into icecream container for refill measurement.
I read 1/2 turn and that was it, how is this done without pulling the cap off the top of the fork tube?
 

jrusell

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Have not done ES forks so I can't comment on procedure.

Ramseybella keep reading, 2 paragraphs down.

Commuter boy I do exactly the same thing. Especially if it is really dirty.
The tenere forks have nice fork spring guides which reduce the spring to fork tube contact. Really helps reduce the metals in the oil. Some older forks without guides created unreal amounts of metal in a very short time.
 
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Joined
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Roatan, Bay Islands, Honduras
Forks are over due for new oil. If seals are not leaking there is no need for new seals. Pick up 1 liter of 5 wt oil and do it yourself in a couple of hours.
Shock is not serviceable in it's current form, so leave it alone.
Thanks, Jrusell, I like the idea of just changing new oil every year. I don’t know how to do it myself and am not mechanically inclined. I live in Central America and the service manager at my local Yamaha shop just quit this week. His assistant gal is telling me I have to change a seal on each fork, but they don’t have it in stock, ( they have the oil)
. That they have to order fork seals thru Mexico, takes 2-3 months, yada, bs, yada, etc. . There is NO front fork oil leakage visible. If it were you in my place, would you just go ahead and tell them to just change the oil w/o changing any seals? Thanks mucho!!! ( I special-ordered my S10 thru them, they do not stock S10 parts).
 

jrusell

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If you can't do it yourself you don't have many options.
22000 miles is a lot on factory oil imo, so a full strip and clean is not a bad idea.

I would not tell any dealer what to do. If this is what they say is needed your only decision is to use them or not. Arguing about what is needed will get you no where.
I would personally visit some other shops if possible. Maybe there is a dirt bike/motorcross shop in the area?

If you don't have a garage of your own and some basic tools then you are stuck paying others to do these tasks.
There is nothing hard about doing a drain and fill on your forks. Hardest part is removing the front wheel. If you can do that the rest is easy.
 
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Checkswrecks

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Scott -
There are a number of Youtube videos about how to replace the fluid. For example:

Replacing fluid is something I do once a year during winter maintenance. At 25,000 miles, your fork oil will be fairly dark if not black. As jrussell wrote, if you can pull the wheel, then removing the forks is quite easy. It is your bie and if the seals are not leaking, I would tell the shop to JUST change the fluid, especially where you are. That said, the bike isnot going to suddenly die if you put it off more. Not many people change the fork fluid during their ownership.

I would strongly suggest ordering the following three things for when you might need them in the future.
1. Shock Sox to protect your seals.
2. A Seal Saver to clean them if they start to leak.
3. A set of new seals, just in case.

While you are at it, order a set of front and rear brake pads. After gas, oil, and tires, they are the next most consumed things on the bike and you will go through those at some point too.
 

gv550

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Many thanks to jrusell for the excellent information. I changed my fork oil and it was quite dirty. I had no difficulty with the the top cap, I found a 15/16 socket actually fit better than my 24 mm and the caps came loose without any damage to the hex.
I let the forks hang upside down for a couple hours after pumping them several times, and got a total of 900 cc so I put 465 cc of new oil in each leg.
 
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Redscorpiondg

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Miami, Florida
Very nice. It would be helpful for the nay sayers if someone posts up pictures of 25,000 km oil to show how foul it gets. I'm always a little astounded at how a sealed environment like inside a fork tube can have fluid and bits break down so much in a relatively short period of time.

The only thing I'd add is that I dump out the oil, measure it, then put in some clean oil, cycle it through, and drain it out to get some extra crud out without a full strip down. Then I add the measured quanitty of new oil in.
thumbnail_IMG_5038.jpg
 
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