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Gen 2 - setting fork oil level

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londonsean69 View Drop Down
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    Posted: 18 Jul 2019 at 18:23
Evening all

One of my fork seals has gone, so I have a new set of oil and dust seals, and some 7.5wt fluid, plus  new tools :)

One question; When setting the fork oil height, what should be in the fork leg? Damper and spring? The manual isn't clear on it.

Cheers

Sean

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Sean

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Spoonz View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Spoonz Quote  Post ReplyReply Direct Link To This Post Posted: 18 Jul 2019 at 18:40
Officially they take 500ml per keg but go by oil height not quantity as there will be oil trapped still in the cartridge etc. Fit the spring and raise the damper rod, then fill to 85mm from the lip of the stanchion
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Post Options Post Options   Thanks (0) Thanks(0)   Quote londonsean69 Quote  Post ReplyReply Direct Link To This Post Posted: 18 Jul 2019 at 23:53
Originally posted by Spoonz Spoonz wrote:

Officially they take 500ml per keg but go by oil height not quantity as there will be oil trapped still in the cartridge etc. Fit the spring and raise the damper rod, then fill to 85mm from the lip of the stanchion
Cheers, I have the syringe type tool to do the air gap.

Quick question though, the workshop manual says (off the top of my head) 120mm air gap +-2mm. Am I right in thinking that is the air gap with no spring, and that the spring will raise the oil level about 35mm?
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Sean

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Post Options Post Options   Thanks (0) Thanks(0)   Quote Spoonz Quote  Post ReplyReply Direct Link To This Post Posted: 19 Jul 2019 at 10:50
I’m guessing it’s not an aprilia manual as they only give the air gap with spring installed. But yes I would guess the spring would raise it by that much
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londonsean69 View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote londonsean69 Quote  Post ReplyReply Direct Link To This Post Posted: 20 Jul 2019 at 19:30
Spoonz, thanks for that. Set to 85mm air gap with the spring in and the damper rod up.

The whole process went quite well for a first time, although I did have to run out and buy a deep 32mm socket  to clear the preload adjuster when undoing the fork top.

However, when pushing up and down on the forks with the front brake engaged I am now getting a very gentle click. Will investigate further tomorrow.

Cheers
Sean

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Post Options Post Options   Thanks (0) Thanks(0)   Quote Spoonz Quote  Post ReplyReply Direct Link To This Post Posted: 20 Jul 2019 at 20:01
The click might be in the cap. If so either the nut needs nipping up or you might have to shim it. One leg on mine needed shimming from new for the same reason. Look for the blue anodised bit moving slightly within the cap. 
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londonsean69 View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote londonsean69 Quote  Post ReplyReply Direct Link To This Post Posted: 20 Jul 2019 at 20:28
Originally posted by Spoonz Spoonz wrote:

The click might be in the cap. If so either the nut needs nipping up or you might have to shim it. One leg on mine needed shimming from new for the same reason. Look for the blue anodised bit moving slightly within the cap. 


Cheers, I'll give it a look tomorrow.
Cheers

Sean

A few of my pics - www.arrowpix.com
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