XL600V-H to V-R (1987 to 1995) and XRV750-L to S (1990 to 1995) models
Note: The forks fitted to early models are equipped with an oil drain bolt at the lower rear face of each fork slider, enabling the oil to be changed without removing the forks from the motorcycle.
1. Position a container below each fork leg drain bolt and have ready a piece of card or similar to direct oil away from the tyre during draining. Remove the drain bolt from the fork slider and, with the bike off its stand, pump the forks to expel the fork oil into the container.
2. On completion of draining, refit the drain bolts with their sealing washers, and tighten them securely. Renew the washers if necessary.
3. Displace the handlebars from the top yoke as described in Section 5. Unscrew the top bolt from the top of each fork (see illustration 7.10).
Warning: The fork spring is pressing on the fork top bolt with considerable pressure. Unscrew the bolt very carefully, keeping a downward pressure on it and release it slowly as it is likely to spring clear. It is advisable to wear some form of eye and face protection when carrying out this operation.
4. On XL600 models, withdraw the spacer, spring seat and the spring from the tube. On XRV750 models, withdraw the upper spring, spring seat and lower spring from the tube. Note which way up the spring fits.
5. Working on one fork at a time, slowly pour in the specified quantity of the specified grade of fork oil and pump the fork at least ten times to distribute it evenly (see illustration 7.14). When both forks have been filled, fully compress the front end so that the fork tubes are fully compressed Into the sliders, then measure the oil level. Check that the level is the same in each fork and that it is as specified at the beginning of the Chapter.
6. Extend the forks, then install the spring with its closer-spaced coils at the bottom. On XL600 models now install the spring seat and the spacer. On XRV750 models install the spring seat and the upper spring.
7. Fit a new О-ring to each fork top bolt and thread the bolts into the top of the fork tubes (see illustration 7.16). Screw each top bolt carefully into its fork tube making sure it is not cross-threaded, then tighten it to the specified torque setting.
Warning: It will be necessary to compress the spring by pressing it down using the top bolt to engage the threads of the top bolt with the fork tube. This is a potentially dangerous operation and should be performed with care, using an assistant if necessary. Wipe off any excess oil before starting to prevent the possibility of slipping.
8. Install the handlebars (see Section 5).
XL600V-T models onward (1996-on), XL650V models and XRV750-T (1996-on) models onward
9. Remove the forks (see Section 6). Always work on the fork legs separately to avoid interchanging parts and thus causing an accelerated rate of wear (see illustration 8.1a or b).
10. If the fork top bolt was not slackened with the fork in situ, carefully clamp the fork tube in a vice equipped with soft jaws, taking care not to overtighten or score its surface, and slacken the top bolt (see illustration).
![](https://motoinstruction.ru/img/honda/19/125688.jpg)
7.10. Thread the top bolt out of the tube
11. Unscrew the fork top bolt from the top of the fork tube.
Warning: The fork spring is pressing on the fork top bolt with considerable pressure. Unscrew the bolt very carefully, keeping a downward pressure on it and release it slowly as it is likely to spring clear. It is advisable to wear some form of eye and face protection when carrying out this operation.
12. Slide the fork tube down into the slider. On XL600 and 650 models, withdraw the spring from the tube (see illustration). On XRV750 models, withdraw the upper spring, spring seat and lower spring from the tube. Note which way up the spring fits.
![](https://motoinstruction.ru/img/honda/19/125689.jpg)
7.12. Remove the spring
13. Invert the fork over a suitable container and pump the fork tube vigorously to expel as much oil as possible (see illustration). Support the fork upside down in the container for a while to allow as much oil as possible to drain, and pump the fork again.
![](https://motoinstruction.ru/img/honda/19/125690.jpg)
7.13. Invert the fork over a container and pump the tube to expel the oil
14. Slowly pour In the specified quantity of the specified grade of fork oil and pump the fork at least ten times to distribute it evenly (see illustration). Fully compress the fork tube into the slider and measure the oil level, and make any adjustment by adding more or tipping some out until the oil is at the level specified at the beginning of the Chapter.
![](https://motoinstruction.ru/img/honda/19/125691.jpg)
7.14. Pour the oil into the top of the tube
15. Clamp the slider In a soft-jawed vice using the brake caliper mounting lugs, taking care not to overtighten and damage them. Pull the fork tube out of the slider as far as possible then install the spring with its closer-spaced coils at the bottom (see illustration 7.12). On XRV750 models, now install the spring seat and the upper spring.
16. Fit a new О-ring to the fork top bolt and thread the bolt into the top of the fork tube (see illustration).
![](https://motoinstruction.ru/img/honda/19/125692.jpg)
7.16. Fit the top bolt using a new O-ring
Warning: It will be necessary to compress the spring by pressing it down using the top bolt to engage the threads of the top bolt with the fork tube. This is a potentially dangerous operation and should be performed with care, using an assistant if necessary. Wipe off any excess oil before starting to prevent the possibility of slipping. Keep the fork tube fully extended whilst pressing on the spring. Screw the top bolt carefully into the fork tube making sure it is not cross-threaded.
Note: The top bolt can be tightened to the specified torque setting at this stage if the tube is held between the padded jaws of a vice, but do not risk distorting the tube by doing so. A better method is to tighten the top bolt when the fork has been installed in the bike and is securely held in the bottom yoke (see illustration 6.8).
Use a ratchet-type tool when installing the fork top bolt. This makes it unnecessary to remove the tool from the bolt whilst threading it in making it easier to maintain a downward pressure on the spring.
17. Install the forks (see Section 6).