2005 S4R For Oil Level

[Derekv]

Best I have found is either 108mm or 132mm.  What is the correct fork oil level?  I have a bad seal, parts are on the way.

Derek V

[EEL]

132mm from top???

Seems really low.

I would go 108mm from top. If you want to run stock look in the factory service manual. It will give you a volume. Pour it in and measure and see which one it falls closest to. 108 or 132. Since you will have residual fluid in the fork anyways, youll have to suck down to get to that value.

[Derekv]

108mm it is. I am surprised it is so difficult to find the oil level online somewhere.

Derek V

[EEL]

Message me if you want a link to the workshop manual.

.492 liters per fork leg

[EEL]

Its been a long time since I worked on this model fork so a couple of lessons learned.

I would be careful with the reinstall of the fork cap. You have to set the rebound adjuster to the appropriate amount of clicks first before installation of the cap back on. Also, be careful of how you tighten. You have to back out the rebound adjuster after you hand tighten the cap to the damper rod. Otherwise you'll ruin the brass needle.

Also, you'll need a spring compressor to get to the fork cap locknut under the long spacer at the top. You cant create your own by taking a piece of steel pipe and drilling and tapping some threaded rod of appropriate size to fit thru the holes in the spacer.

I cant remember if you need to measure the fork oil with the spring or without. fork has to be fully compressed down to its stop first. Add oil, see where the volume sits and then you should be able to figure out if the spring is needed. I think it does need to be in there.

[Speeddog]

My shop manual says 104mm, FWIW.

Definitely with no spring.

[Derekv]

104mm, spring not installed, yep.  Thanks for the link Eel.

Doesn't look too bad.  Go slow, take notes & pics.  Should have all the parts early next week.

Derek V

[Derekv]

News seals in both forks, new oil.  Reset all front suspension settings to factory settings.  Bike handles much better.  I'll make small adjustments and get the forks dialed in.

Derek V