K11 Owners Group

Jnclem · Posted: Fri Oct 14, 2016 9:46 pm Post subject: Another fork Question

A few weeks ago, I set out to simply replace the seals and install gators on my K1100LT forks. Unfortunately, I got everything jammed up on one side when a lower bushing got deformed. I was able to remove the lower with heat, and without having to cut it in half, so that was good.

I now have new lower bushings, and another set of new seals installed, and I'm getting ready to reassemble everything. I HAVE NOT removed the fork legs, or disassembled them, I have just pulled the lowers off. However, the lowers have been off now for three weeks. Do I need to refill according to the changing the fork oil instructions, or according to the disassembly instructions? In other words, do I need to refill with 350 and 400 cc's, or with 400 on both sides?

Thanks.
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'93 K1100LT, '89 R100GS

Scott_Anderson · Posted: Fri Oct 14, 2016 11:08 pm Post subject:

Me, I'd fill per the "disassembly" instructions.
Now, as far as the "assembly", as one who has had problems with installing seals while the uppers are still mounted in the bike----I'd strongly recommend removing the upper from the bike to allow you to install the seal over the entire length of the upper.
This really ensures that you don't "fold over" either lip of the seal and damage it.
BTDT.... just sayin- to save you heartache.
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Ride safe.

1995 K1100LT 0302044
1997 R1100RT ZC62149
2017 FLHTK Ultra Limited
Garmin StreetPilot 2820
Garmin Zumo 550
Garmin Zumo XT
"One who does not ask questions is ashamed to learn" Danish proverb
1997 K1100LT 0302488(R.I.P.)

Corkboy · Posted: Sun Oct 16, 2016 4:01 am Post subject:

Fill as per the disassembly quantities.

The 50cc of a difference between the two measurements is what pours out of the one leg when you undo the allen bolt holding the lower stanchions in place.

If you only drain the leg and refill - that amount stays in the leg, hence the difference.

Went through the same question and realised that once you take the legs apart there is absolutely no oil left in the forks, so you are doing a complete fill. If you are not taking the legs apart, the 50cc stays trapped and doesn't come out.
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'08 K1200GT
'87 K100RS 0140995 (Gone)
'97 K1100LT 0188024 (Gone)
'08 Transalp 700 (Gone)

Jnclem · Posted: Sun Oct 16, 2016 3:49 pm Post subject:

Jnclem · Posted: Mon Oct 17, 2016 8:17 am Post subject:

Thanks for the help. I refilled with 400cc's per side, and all seems to be working great as far as the new seals and bushings go.

Unfortunately, I managed to pinch my front sensor wire between the fork bridge and the mints on the sliders. I now have a flashing ABS light. I guess I will be looking for a new front sensor.

Sigh...
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'93 K1100LT, '89 R100GS

Corkboy · Posted: Wed Oct 19, 2016 2:36 pm Post subject:

Jnclem · Posted: Wed Oct 19, 2016 5:18 pm Post subject:

Yes, I did check the gap, and it's fine. I mashed that sensor cable, and I am getting a code 3, front sensor fault. It's the sensor.
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'93 K1100LT, '89 R100GS