progressive fork oil volume

[Oregonbaron]

Hi all,

I'm kind of new to the forum (I joined a while back but I haven't posted anything, yet), so I'm not sure if I'm doing this right. I've got a '95 voyager 1200 with 50,000 miles which I'm enjoying a lot.

I decided to do the progressive fork spring upgrade. Rather than taking the forks off, I opted for the method of leaving the forks on the bike and making a tool to depress the top of the fork. It worked great and I have the new spring in.

The problem is that I'm not sure how much fork oil to put in. Most of the guidelines I've seen talk about measuring from the top of the upright fork. However, since the fork is still on the bike, I have no way to get the fork level. So, I was planning on adding the oil by volume. I've read that 330mL is the recommended Kawasaki volume when the fork is not disassembled, but is this volume still correct with the progressive springs in there instead of the stock springs? If not, what is the correct volume of oil when using progressive springs?

Thanks for your help with this. This forum has a ton of great people and lots of knowledge!

Don

[chevyman1]

I use a hand held vacuum pump (mighty-vac) hooked to a peace of tubing with a stop on it overfill the tubes and then suck the oil out until the desired level.
I use 145mm from top, tubes compressed without the springs in.
I always take the tube off the bike,It's doesn't take that long and it's not hard to do plus you can clean them out easier.

[Avidrider62]

And Carl Leo recommends 145mm from top, 140 if progressives used. I'm in the middle of finishing mine up tomorrow, using ATF

[voyager55]

I change fork oil using Jeff Barnhill's guide. Simple & Easy

http://www.abbikeboard.com/jeff/spring/spring.html" onclick="window.open(this.href);return false;

[Oregonbaron]

For those that use Jeff Barhill's method of leaving the fork on the bike, do you use the 352 mL volume for refilling the fork oil like he lists for '87-'03 voyagers that have switched to progressive springs?

[voyager55]

Yes, It's like 11.9 ounces if i remember correctly

For those that use Jeff Barhill's method of leaving the fork on the bike, do you use the 352 mL volume for refilling the fork oil like he lists for '87-'03 voyagers that have switched to progressive springs?

[Oregonbaron]

Thanks for all the replies and information! I will try and get the job finished up tonight.

[SgtSlag]

Is Jeff quoting the Kawasaki manual, using Kawasaki springs? If so, then the volume specified (11.9 oz.), is likely too much. Progressive specified a maximum oil height, from the top of the level tube, as 5.5", regardless of the factory specifications. More than that, and you risk blowing the seals on the tubes.

Bottom line: does the 11.9 oz. work, without blowing the seals? If it does, then nothing else matters. Thanks. I plan on changing the fluid in mine soon, but I don't remember how much I put in when I installed the Progressive springs. Cheers!

[chevyman1]

I would use the distance from the top method because the volume in the fork tubes can vary.
the larger that distance the more air space you will have.
you don't use air presser with Progressive springs but there is still air pressure in the forks.
I would use the 145mm that is recommended it the tech section to start.

[voyager55]

I've used the 11.9 ounce amount for years without problems

Is Jeff quoting the Kawasaki manual, using Kawasaki springs? If so, then the volume specified (11.9 oz.), is likely too much. Progressive specified a maximum oil height, from the top of the level tube, as 5.5", regardless of the factory specifications. More than that, and you risk blowing the seals on the tubes.

Bottom line: does the 11.9 oz. work, without blowing the seals? If it does, then nothing else matters. Thanks. I plan on changing the fluid in mine soon, but I don't remember how much I put in when I installed the Progressive springs. Cheers!

[Ohio Mike]

I've used the 11.9 ounce amount for years without problems.

Is that 11.9 ounces with stock or Progressive springs?

Ohio Mike

[voyager55]

With progressive springs

[kjsett]

I've used the 11.9 ounce amount for years without problems.

Is that 11.9 ounces with stock or Progressive springs?

Ohio Mike

So, I am hoping to do the front this winter (still a riding season here in Phoenix, just can't go anywhere). It sounds like you can do the "volume method" with the forks still on (???), whereas the distance method requires the forks off (??).
Really, winter is repair season only because of it's too hot to do any optional work on my '03 during the summer (meaning April to Oct).

[ghostler]

I would use the distance from the top method because the volume in the fork tubes can vary. the larger that distance the more air space you will have. you don't use air presser with Progressive springs but there is still air pressure in the forks. I would use the 145mm that is recommended it the tech section to start.

Instructions that came with mine said to follow factory specs for oil height, but definitely not more oil than the 145mm air gap will permit. I used the 160mm figure in the A1 (1986) manual. I didn't think to check the supplement, which for models B1-B17 (1987-2003) specifies the 177mm figure. Since the Progressive springs take more volume, which would raise the oil level higher than with the standard springs, wouldn't it be safer to go with the 177mm (6-31/32in) or 160mm (6-9/32in) values?

Regardless, at the 160mm oil height for my B15 (2001), today I just finished a 480 mile round trip from Clovis NM to Munday TX and back. New fork seal on left side held, ride was much smoother than with the old OEM air ride springs. I'm going to like these springs.