February 5, 2011.
I got the springs and other things in from Traxxion Dynamics earlier this week and
today I replaced the fork seals in my 2002 GL 1800, Goldwing. It took 9 years and
80,000 miles but the left seal finally went. The Hinda service manual says that the
oil never needs to be replaced unless it is leaking from a fork. It is suppose to be a
lifetime oil. Hmmmmmm......never really understood that.
Here's how it's done.
Bike is lifted off the ground and secured.
This is the anti dive unit. It is only on the left fork and it is the one that leaked.
The general thought is that this thing malfunctions and cause too much pressure on the
fork seal causing the blow past effect.
Oil on the upper tube.
The top portion of the anti dive is taken apart. The odd thing about this device is
that the top portion of the valve operates on brake oil and the botton portion operates
on fork oil. When the brakes are applied, the fluid pushes this plunger down into the
fork oil thus causing the front end to not dive as much. It mostly tries to compensate
foor the weak fork springs that Honda put in the Goldwing.
After I removed the front wheel and the calipers from the fork tubes, I didn't want the
calipers dangling from the brake lines, so I zip tied them up.
The upper fork bolts and caps are under this, so it must come loose.
After you loosen the upper and lower pinch bolts, you slide the fork tubes out.
You take the cap off easy, there is a pretty good bit of pressure behind it. You then
remove a spacer, spring spacer and the spring, then pour out the oil. It was really
nasty and stunk.
After the oil is drained out, you must remove this bolt from the bottom.
It is a 6mm and is in way too tight to remove with an allen wrench. I then sacrificed
another wrench that I had and made this tool. Worked just fine.
After the bolt is removed, the entire upper fork slides out.You then remove the fork
seal large washer and bushing.
The lower bushing showed signs of wear, just as Traxxion said it would, so I replaced
it with a new one.
All the internals.
Now all the new parts must be put back in and the order is simply reversed.
Old Honda spring on top, new Traxxion spring on bottom. The new one is much beefier.
The fork seal requires a special tool to properly seat the seal and the bushing in the
lower fork sleeve. Not having this tool, I got creative. I got a piece of 2" PVC
pipe, a 2" to 1 1/2" reducer and a 2"cap. It is a trademarked item as you can see.
It is then slid over the tube down to the fork seal.
You then tap the top and the fork seal seats perfectly!
BEFORE all the parts are put back in, oil must be put in the forks. I used 15 weight
fork oil. The Goldwing oil measurement system is different than most bikes. You do
not fill the forks with a preset amount of oil, the oil must be measured from the top
of the fork down to the oil. With the Traxxion springs the distance is 125mm from the
top, with the Goldwing springs it is 128 mm. There is a tool you can buy for this
measurement, but I decided to make some with some things I had lying around. I got a
large syringe, a thin piece of wood and some tubing.
I then cut a hole in the wood shim, inserted the tube in the hole, and then measured
the distance from the bottom of the wood to the bottom of the tube. I then slid the
wood down until it was 125mm from the bottom of the tube.
I then inserted plastic tube into the fork and sucked the oil out of the tube. I
sucked until no more oil came out, then I knew it was 125mm from the top.
All the parts back together, then tighten the cap.
In order to disbale the anti dive, I simply cut the pluger off with a Dremel. It will
be permanently disabled, but it is not necessary with the new springs.
The forks are then slipped back in, pinch bolts tighten, all the brake components put
back on the and the upper shelter reassembled.
The strange thing is that when I finished, I had some bolts left over?
If anybody wants or needs this done to their wing, let me know and I can help you