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Fork Oil change on a 2002 GL1800

Complete GL1800 Maintenance video now available at
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Bike jacked and front fender and caliper covers removed
Bike jacked and front fender and caliper covers removed		 Removing the lower left brake caliper bolt with an allen socket bit
Removing the lower left brake caliper bolt with an allen socket bit		 You need a torx bit to remove the upper bolt on the left brake caliper
You need a torx bit to remove the upper bolt on the left brake caliper		 Torx socket used to remove left caliper.
Torx socket used to remove left caliper.
I used a bungee to tie support the caliper once removed.
I used a bungee to tie support the caliper once removed.		 Removing right caliper with 12mm socket.
Removing right caliper with 12mm socket.		 Removing the axle bolt.
Removing the axle bolt.		 Loosening axle clamp bolts. Notice caliper is supported with bungee to reduce stress on brake lines.
Loosening axle clamp bolts. Notice caliper is supported with bungee to reduce stress on brake lines.
Remove the axle, then just roll the wheel out.
Remove the axle, then just roll the wheel out.		 a 6mm allen wrench is sacrificed. I cut it so it was long enough to reach the bottom bolt through the bottom of the fork leg.
a 6mm allen wrench is sacrificed. I cut it so it was long enough to reach the bottom bolt through the bottom of the fork leg.		 I then put the allen into a 6m socket and ratchet to hold it.
I then put the allen into a 6m socket and ratchet to hold it.		 Now I use my newly made tool to remove the bottom bolts.
Now I use my newly made tool to remove the bottom bolts.
bottom bolts and copper sealing washers.
bottom bolts and copper sealing washers.		 and out comes the oil
and out comes the oil		 Here I loosen the left top triple tree clamp.
Here I loosen the left top triple tree clamp.		 Next I remove the left top cap.
Next I remove the left top cap.
After pulling out the spacer, I fished the spring and washer out with a plastic coated coat hanger.
After pulling out the spacer, I fished the spring and washer out with a plastic coated coat hanger.		 Spring and washer are removed.
Spring and washer are removed.		 Right side fork cap removed and locknut underneath loosened with a 14mm open end wrench
Right side fork cap removed and locknut underneath loosened with a 14mm open end wrench		 spacer, washer and spring come out. Be carefull not to drop the washer down the Honda Hole.
spacer, washer and spring come out. Be carefull not to drop the washer down the Honda Hole.
Right side damper assy simply lifts out. You do not need to remove the left damper, as it doesn't retain fluid anyway.
Right side damper assy simply lifts out. You do not need to remove the left damper, as it doesn't retain fluid anyway.		 Here I have removed the right damper and am pumping all the old oil out of it. Notice oil drained into measurment containers.
Here I have removed the right damper and am pumping all the old oil out of it. Notice oil drained into measurment containers.		 Re-install damper rod once fully drained, and with springs still removed, reinstall and tourque bottom bolts.
Re-install damper rod once fully drained, and with springs still removed, reinstall and tourque bottom bolts.		 Pour in new SS-8 10w Honda (Showa) fork oil. 529 cc's left, 485 cc's right. I purposley overfilled and then removed the excees.
Pour in new SS-8 10w Honda (Showa) fork oil. 529 cc's left, 485 cc's right. I purposley overfilled and then removed the excees.
First pump both fork legs a dozen or so times to get all the air out, then support them fully compressed.
First pump both fork legs a dozen or so times to get all the air out, then support them fully compressed.		 now pump the right damper rod several times to bleed and re-fill the damper with the new oil.
now pump the right damper rod several times to bleed and re-fill the damper with the new oil.		 Continue to pump the rod until you are sure you have all the air out.
Continue to pump the rod until you are sure you have all the air out.		 Mity Vac tool set to 5 inches (128mm) per the manual
Mity Vac tool set to 5 inches (128mm) per the manual
Mity Vac tool with homemade alluminum rod and rubber tip and stop block used to set fork oil level
Mity Vac tool with homemade alluminum rod and rubber tip and stop block used to set fork oil level		 With forks compressed, and springs removed insert the rod to the stop block and draw out the excess oil. Now it is set perfecly.
With forks compressed, and springs removed insert the rod to the stop block and draw out the excess oil. Now it is set perfecly.		 Reinstall the springs, washers, and spacers and top caps and front wheel. Your done!
Reinstall the springs, washers, and spacers and top caps and front wheel. Your done!		 Progressive Springs. Notice I got a set that is not matched in length.
Progressive Springs. Notice I got a set that is not matched in length.
Here is another angle look at them
Here is another angle look at them		 Here is a photo of my last moonshot
Here is a photo of my last moonshot		 LeftForkLeak.JPG
LeftForkLeak.JPG		 preload.JPG
preload.JPG
preload2.JPG
preload2.JPG		 BottomValve 001.jpg
BottomValve 001.jpg		 BottomValve 002.jpg
BottomValve 002.jpg		 BottomValve 003.jpg
BottomValve 003.jpg
GL1800ForkSeal 001.JPG
GL1800ForkSeal 001.JPG		 OldForkSeal.jpg
OldForkSeal.jpg		 ForkSealGrease.jpg
ForkSealGrease.jpg		 LeftForkSealLeak.jpg
LeftForkSealLeak.jpg
click on thumbnails for full image