Draining
Warning: Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.
1. Remove the fork (see page 13-5).
2. Remove the top cap assembly (see page 13-9).
3. Remove the fork spring (see page 13-9).
4. Holding the inner and outer tubes together, invert the fork and pour out the fork oil into a suitable container. Pump the damper rod to remove all the oil.
Oil Refilling
The oil level is measured from the upper surface of the fork outer tube, with the fork fully compressed and the spring removed.
Fork Oil Level (fully compressed)
Model | Oil Level |
Tiger 800 | 103 mm |
Tiger 800XC | 107 mm |
1. Fill the fork with the grade of oil specified in the fork oil table, to a level above that which will finally be required.
2. Pump the fork assembly and damper several times to expel any trapped air then fully compress the fork and support it in an upright position. Leave the fork for a few minutes to allow the oil to stabilise.
3. Refer to the fork oil level chart and set the scale on tool 3880160-T0301 to the relevant distance, as shown below.
Refer to fork oil level chart.
1. Tool 3880160-T0301; 2. Adjustment plate; 3. Scale area; 4. Hole (zero position)
Note: Zero level on the tool is set at the small exit hole in the side of the scale tube, NOT AT THE END TIP. Do not attempt to block this side hole as this will cause the final fluid level to be incorrect.
4. Insert the scale end of the tool into the fork inner tube.
5. Hold the tool adjuster plate level with the upper surface of the fork inner tube and draw fluid into the syringe until fluid flow ceases (empty the syringe if the body becomes full before fluid flow stops).
6. The fluid level in the fork is now set to the height set on the tool scale. Check the tool scale setting and repeat the process if incorrectly set.
Warning: Incorrect fork oil levels could result in an unsafe riding condition leading to loss of control and an accident.
7. Assemble the fork (see page 13-12).
8. Refit the fork (see page 13-6).
Fork Oil Level Chart
Tiger 800
Oil Level* | Oil Volume | Oil Grade | Fork Pull Through |
103 mm | 553 cc | Showa SS 8 | Top of the inner tube 4 mm above the upper face of the top yoke |
Tiger 800XC
Oil Level* | Oil Volume | Oil Grade | Fork Pull Through |
107 mm | 619 cc | Showa SS 8 | Top of the inner tube 4 mm above the upper face of the top yoke |
*Fork Fully Compressed