Fork Oil Levels

[Crimson]

Ok, I got my progressive springs in today, and I am following Pantablo's instructions for changing them out.  I checked the 'air' space as per the instructions with the springs, and they say it should be about 5.5cm max from the top of the tube.  But they also say thats with the forks compressed completely?

What does that mean when I am changing the springs one at a time as per Pantablo's instructions?  My 'air' space is closer to 15 cm, but I think thats probably because they forks aren't compressed.  Any ideas here on how to get proper levels?

[stephan]

Sorry for the length, just trying to be thorough

Okay, here's how I did my fork oil level when I replaced my stock springs with progressive ones, and 15w fork oil.

-  Make sure all the old oil is out by turning the fork upside down and pumping it.  Then let it sit upside down to drain the rest of the way 10-15 minutes.

-  Turn the fork right side up, and compress the fork completely.  Make sure the smooth shinny smaller section is pushed down as far as it will go into the larger textured section.  Now your ready to put fork oil in.

-  With the fork empty (no spring) start putting oil into the fork tube.  I made an oil level guage using some wire shaped like an "L".  I marked the wire with a marker at the desired measurement and bent it.  As I filled the fork, I checked from time to time until the oil touched the very tip of the wire.  When I checked the level the wire actually looked like and upside down "L" with the longer side going down into the tube.

NOTE ON FORK OIL LEVEL: The manual that came with my springs suggested not to make the oil level any smaller than 140mm (14cm).  By this I mean the air space from the oil surface to the top of the fork tube shouldn't be any smaller than 140mm - but this was for MY springs.  Your's may be different.  However if they came from Chaparral than this should hold true.  By making the air space smaller the forks will be harder.  To me, 55mm (5.5cm) seems really small, but if that's what your manual says, I'd go with it.

-  As you fill you'll notice some bubbles coming to the surface of the oil, pump the fork to circulate the oil and get out all the air.  This is the only way I can think of to be positive you have equal oil levels in each fork tube.  While you pump make sure you don't tip the tube over.  You don't want to lose any oil in this step.

-  Once you have all the air pumped out, and you're at the proper oil level you can put your spring in.  Some say to put the more dense end in first, others say last.  My spring manual said it didn't matter.  I put it in with the more dense end at the top of the tube.

-  My spring manual suggested using a spacer length of 3/4".  I simply took my stock spacer and made two 3/4" spacers from them.  Others have had good results from PVC spacers - it's entirely up to you.

-  With the proper oil level, air bubbles out, spring in, spring washer it, and spacer in, you can put the fork cap back on.

That's it, your done!  Repeat for the other tube and enjoy your upgraded suspension!

[Crimson]

My problem is I am not removing the fork tobe..  How am I supposed to turn them over?  Heh..  Actually, I just threw the springs in there, made 3/4" spacers, and slapped everything back together.  The space is greater than the recommended minimum, so I should be OK..

Besides, even progressives with not enough oil have to be better than that stock piece of crap spring!

[Kerry]

Ok, I got my progressive springs in today, and I am following Pantablo's instructions for changing them out.  I checked the 'air' space as per the instructions with the springs, and they say it should be about 5.5cm max from the top of the tube.  But they also say thats with the forks compressed completely?

What does that mean when I am changing the springs one at a time as per Pantablo's instructions?  My 'air' space is closer to 15 cm, but I think thats probably because they forks aren't compressed.  Any ideas here on how to get proper levels?

5.5cm is too small of an "air space" with the forks fully compressed, and the springs out.  The spec. for the stock setup is 99mm!

In the instructions that most people mention from their Progressive package, the measurement is 140mm - again with the springs out and the forks fully compressed.  (You DID get the 1178 springs, right?)

Perhaps the 5.5 cm measurement is with the springs IN.  With the forks extended? ..... Who knows.

Someone who needs to replace their fork seals (hmmmm, that would be me  :x ) really ought to set up all these scenarios and take some measurements with and without the (stock and Progressive) springs, compressed and uncompressed, etc.

Sigh - one of these days....  :dunno: