1.) lift the front off the ground with a headstock stand or from roof rafters.
2.) remove front wheel, take of brake calipers and speedo sensor.
3.) remove handlebars and make sure they are vertical (don’t want your brake juice going everywhere).
4.)Undo the pinch bolts on the top yoke (or it wont work), then using the fork tool undo the top part of the suspension JUST SO ITS LOOSE, the bottom clamp holds it in place this saves you having to put it in a vice once removed.
5.)Undo bottom yoke pinch bolts and remove fork legs.
6.)Unscrew the top part of the fork until the outer black fork stanction falls down.
7.) you now should see a long 5” spacer this needs to be pulled down to reveal the 22mm nut helps if you have two people, you need a THIN spanner an adjustable one probably wont work.
8.) with the 22mm spanner on you can now use your tool in the tool kit to unscrew the top preload which lets the top cap fall off.
9.) as you remove the 22mm spanner the 5” spacer, and spring just slide out, put all the parts to one side.
10.) the oil can then be poured into a container make sure you pump the inner part as shown or you wont get all the fluid out.
11.) once your happy you have all the fluid is out replace with 5w fork oil 1 litre is enough to do both forks and some left over.
12.) fill up with new oil it does not matter if you put too much in but hopefully you noted the oil level prior to removing, Make sure you pump the inner workings to get the oil in the chambers as you did when you removed the old oil, we use a device to get the correct air gap, here is one I made, you can buy the device but this works the same.
Then place inside the fork tube and it sucks the excess oil out to the desired 11cm gap.
The air gap is meant to be 11cm, the air gap is from the oil level to the top of the outer suspension sleeve when at the bottom of the fork stanction the fork should look like this when measuring:
Make sure you pump the inner workings to get the oil in the chambers as you did when you removed the old oil..
13.) Ok you now have fresh oil, I have an 06 bike so changed my front 9nm springs for 9.5nm which the 07 on and SDR has. You now just need to reverse all the steps to put it back together. I got sent the wrong springs by FTR they were for an RC8 so not actually put back together yet!
Will be changing my rear spring too some time this week from a 160 to a 170.
Sorry for the crappy pics, my camera is gash and hard taking pics of yourself when you need both your hands! I also apologise I never know the correct word for anything but hopefully you get the jist, not a difficult job IMO.
