Note: While you have it apart make sure you check your steering bearings. If they're worn or dry replace them. All Balls Racing Products
The procedure for replacement can be found at SteeringBearing.html
This procedure requires the bike to be on a bike lift.
This procedure is best done with 2 people!!!!!!!
Disassembly
1. Remove the front brake master cylinder from the handlebar. (wrap in a towel to protect from damage)
2. Lay a thick towel on the fake tank covers and console
3. (OPTIONAL) Remove the handlebars by either removing the riser caps or removing the risers from the triple tree and lay them on the tank
4. Remove the steering stem nut with a 30mm socket (see Figure 1, part C)
5. Remove the 2 fork tube nuts with a 27mm socket (see Figure 3, part A)
6. Remove the 4 upper bolts on the chrome cover (see Figure 1)
7. Using a rubber hammer tap upward on the triple tree and remove (if handlebars are still on triple tree place the assembly onto the console/side covers. (see Figure 1, part 5)
8. Remove the headlight (see Figure 2)
9. Remove the turn signal bar (see Figure 2)
10. Remove the 4 lower bolts on the chrome cover (see Figure 1)
11. Slide the chrome cover up and off (see Figure 1, part 11)
12. Remove the steering stem adjuster nut using a pair of channel lock pliers, vise grips… (see figure 1, part 6)
13. Remove the upper bearing seal (see figure 1 , part 7)
14. Jack the bike up slowly and the front end should drop down. The whole front end should be off now. Remember to have someone holding the fork assembly while you jack it up to guide it out.
15. What I did now was get 4 car jacks and raised two of them up high and 2 down low, covered the tops with cloth and lay the forks on them with the top part angled downward. (Put a drain pan under the lower end too)
16. Remove the 2 fork spring retainers nuts inside the upper fork with a 14mm allen type socket (do it carefully and slowly there is spring tension on them. (se Figure 3, part B)
17. Now you can slide the old springs out SLOWLY because the oil is going to come out with them. (I then let mine drain for about an hour) (see Figure 3, part 2)
18. Job well done!
Reassembly
1. Have the forks setting upright, level and compressed, then add new fork oil to the forks approx 14.8 oz. per fork. You can ensure your amount by measuring the oil level in the forks. The oil should be 6.65" or 169.0mm from the top. I used a tape measure and a flashlight to check it. (make sure the forks are level when measuring) (see Figure 4)
2. Install the new springs
3. Place your 3.75" spacers in the fork tube
4. Reinstall the spring retainer nuts and snug them up
5. Reinstall the fork assembly back into the steering stem tube and put the steering stem adjuster nut back on and snug it up.
6. Lower the bike down onto the floor to put pressure on the front end. Here's where your supposed to tighten the adjuster nut to 32.5 ft. lbs. But if you don't have the special tool to do so your gonna have to guess. So use you pliers to tighten the adjuster nut to what you believe is approx. 32.5 ft. lbs. Now move the fork assemble left to right 7 or 8 times then check your adjuster nut to ensure it's still tight. Once it feels good and snug back it off ¼ turn or to where the tension feels right. Like I said without the tool your going to have to use your instincts for this part. (I would suggest maybe turn it back and forth a few time before disassembly to get a fell for the proper tension.
7. Slide the Chrome cover back onto the fork and lower it out of the way.
8. Place the bearing seal back over the upper bearing
9. Reinstall the upper triple tree and reinstall the steering stem nut and snug up
10. Torque the spring retainer nuts to 25.5 ft. lbs.
11. Reinstall the 2 fork tube nuts and snug up.
12. Torque the steering stem nut and fork tube nuts to 65 ft. lbs.
13. Reinstall the chrome cover, turn signal mount and headlight assembly
14. Reinstall the handle bars and front brake master cylinder
15. Go for a long ride and relax for a while!!!!!!!
This may be an easier way . Let me know what you think. Both of these procedures require the bike to be on a bike lift. These procedures are best done with 2 people!!!!!!!
Alternative Procedure
1. Remove the 2 fork tube nuts (27mm socket) (see Figure 3, part A)
2. Remove the 2 spring retainer nuts inside the fork tubes (14mm allen head socket) (see Figure 3, part B)
3. Remove the springs (see Figure 3, part 2)
4. This is the tricky part you'll need something to suck ALL the fluid out of the forks.
5. Add new fluid approx. 14.8 oz. This is where you'll need to be precise to ensure you don't overfill or underfill the forks. (see Figure 4)
6. Install new springs
7. Place your new 3.75" spacers
8. Reinstall the spring retainer nuts and torque to 25.5 ft. lbs
9. Reinstall the fork tube nuts and torque to 65 ft. lbs.