|2004 MOTO GUZZI CALIFORNIA EV TOURING
FORK OIL CHANGE PROCEDURE
REQUIRES 485ml OF SAE 10 FORK OIL FOR EACH FORK
1) Put the motorcycle on the centerstand. Put a jack under the oil sump with a block of wood between it and the bottom of the sump and jack up the motorcycle until the rear wheel is just touching the ground. The front wheel will be off the ground and you will have enough clearance to remove the forks.
2) Remove the fairing.
3) Remove both front brake calipers and carefully set them over the exhaust pipes so that they cannot fall.
4) Remove the front wheel.
5) Remove the four bolts from the lower fork brace (the piece that the fender is attached to). Carefully (no scratches) remove the fork brace with the fender attached. You will have to rotate the lower part of the forks 1/2 turn so the assembly can slide out between them.
6) Loosen the upper pinch bolt.
7) Loosen the fork cap 1/2 turn or so. They aren't very tight so a 12" crescent wrench will do the job nicely. Don't worry, they're NOT spring loaded.
8) Loosen the lower pinch bolts.
9) Remove the fork by pulling it down out of its clamps. Using a large screwdriver, gently pry open the space in the lower fork clamp a very small amount and the fork will slide out much easier and you won't be so likely to scratch it.
10) Completely unscrew the fork cap and pull it up as far as it will go. It does not come completely off. Take care not to damage the O-Ring.
11) Turn the fork upside down and the oil will come running out. When it stops draining turn the fork right side up and pump it several times. Turn it upside down again and more oil will come out. Do this until no more oil comes out.
12) Measure out 485ml (or cc, they are same-o same-o) and slowly pour it into the small opening at the top of the fork. A small funnel fashioned from aluminum foil works well.
13) Coat the O-Ring with a little of your new oil on the tip of your finger and screw the fork cap back in far enough that the O-Ring makes a good seal. Don't worry about tightening it all the way, you will do that later.
14) Slide the fork back up through its clamps (prying with the screwdriver again) until the fork cap is completely through the upper clamp.
15) Snug down the upper pinch bolt enough to hold the fork firmly in place.
16) Tighten down the fork cap. Don't overtighten it as there is no strain on it and the O-Ring makes the seal.
17) Loosen the upper pinch bolt again and get the fork positioned to the point where the bottom of the fork cap is just showing above the clamp. Rotate the fork so your adjusters are lined up the way like them. Tighten down the upper pinch bolt.
18) Tighten the lower pinch bolts.
19) Repeat steps 6-18 on the other fork. Make sure when you have both forks reinstalled that they are as close as possible to the same height.
20) Replace the fender/lower fork brace assembly.
21) Replace the front wheel.
22) Replace the brake calipers. Pump the front and rear brakes a few times.
23) Remove the jack from under the motorcycle.
24) Straddle the bike, grab the front brake, and pump the front end up and down several times.
25) Remove the two Phillips head vent screws from the fork caps to release any air pressure and replace them.
26) Replace the fairing.
27) Go for a ride.
Bob (I'd rather be camping) Schantz