Join Date: Dec 2005
Location: Gold Coast, Australia
It's easy if you don't have OCD and don't mind cheating. And much easier with a centre stand than without.
Take the weight off the back (bag of cement in the top box and tip the bike back works for me). Undo the two pinch bolts on the upper triple clamps, put a towel on the tank, take the handle bar clamps off but just lift, move back and rotate the bars back and lay them on the tank, a bungee cord to hold them still is a good idea. I use a hobby knife and slide it under those caps on the bolts, don't drop them they get lost easily.
Back the preload adjusters on the fork caps right off.
Use a GOOD socket set, undo the top fork caps. This is where the weight MUST be off the front.
Use something like a clean stick (chopstick, Satay stick) measure the existing oil level.
IF it smells like a swamp in there, you need to do more work, so put it back together now and read up on the proper way otherwise continue ...
Push the front of the bike back down, pull the spacer washer and springs out. (Paper towels and newspaper on the floor is useful here).
Use an oil transfer pump (hand pump and an empty plastic soda bottle works fine) pull out the oil you can get to. (This is where not having OCD helps).
Add SOME new oil at this point, enough so that when you rock the bike back you don't suck air below the damper.
Rock the bike back to unweight the front again, pop the springs, washers and spacers back in and using the magic stick plus a torch, top off the oil to the level you marked earlier.
Push the caps back on and VERY CAREFULLY tighten them. They will cross thread if you get careless but if you wound the preload off earlier only slight downward pressure is needed to get them back in. Adjust the preload to where it was, or in my case (~90kg) 'just touching' works.
Tighten the upper pinch bolts again, reinstall the bars. Done.
5 minutes the second time.
If you have OCD and want to do it properly, budget a day.