250-500cc 96 model conventional fork info needed

[Darrel78]

I'm looking to replace the fork seals on my 96 WXE 360; it has the conventional forks. Seems I want 7.5 wt. oil; how much? Do I simply measure out some quantity of oil or measure oil level? I've a copy of the 99 service manual but it doesn't cover this style of fork. Thanks in advance for the help!

 

[dhallilama]

don't have the measurement at the moment, but measuring the fork oil level is X CM down from the fork top with the spring removed. i'll check and see if ive got the measurement in the shop...

fork oil seals: parts unlimited 04070026

 

[fletchman45]

Simple dude. Give a good dealer a call. Such as halls and ask to talk to a technician get the amount and viscosity then transfer back to parts and have it in a few days...I remember those forks well! I had a 96 wxe 250 with revalved right side up conventional zokes.. .loved them good flex and awesome in the woods and adjuster on top....nice.

 

[dhallilama]

from a '96 service manual:

sae 10wt
180mm (springs removed, forks bottomed)

 

[2premo]

if memory serves me those were 45MM forks, here is a service manual from the maker, hope some info in here helps

 

[Darrel78]

Thanks guys!

 

[Darrel78]

So, the service manual is for USD forks; I'm working with conventional forks. How do the springs remove? I see on the shaft a square shoulder but what stops the shaft from spinning?

 

[2premo]

hold that square section with a wrench and remove the cap as memory serves
sorry about the wrong manual, i have the Magnum manual in one of my computers, i will take a look

 

[Darrel78]

Thanks, 2Premo. I contemplated that but was concerned about the assembly of the cap area.

 

[ohmygewd]

hold that square section with a wrench and remove the cap as memory serves
sorry about the wrong manual, i have the Magnum manual in one of my computers, i will take a look

Same s you would with USD forks.

Here's a link to the part catalog for the 98 WR360, it doesn't tell you how but at least it's a good reference
https://www.dropbox.com/s/eajbrihtixoa98d/98_wr_250-360.pdf?dl=0

 

[2premo]

all i could find was the 50mm, because that was on my 98
do you want that, they are similar jus bigger

 

[2premo]

do you have the owners manual, they are pretty good on this part

 

[Darrel78]

I don't have an owners manual so, yes, please. I've no idea on adjustment procedures so the owners manual would answer those questions. The service manual would be great as well. Too much information should be just right in this case. Do you guys fit grease zerks to the steering stems?

 

[2premo]

http://johnandgina.smugmug.com/Motorcycles/Marzocchi-Magnum-50/7908233_cKFKnW#!i=512933340&k=Wk7MFnz
here is a link to a pdf on the 50's
not sure where mine is but looks the same
no zeros on the steering head, clean and inspect the bearings repack if they look good, use waterproof marine grease if worried about water

 

[Darrel78]

 

[ohmygewd]

Same as USD mate, to get the right oil height is the same procedure you would with USD except you are pumping the stantion as oppose to the body. The only key difference is that some conventional forks have bleed holes to the main body and some don't so the oil height can vary...best way, fill her to the top leaving a 5mm gap and pump the forks to bleed the air out, then at fully compressed, measure the oil height and this will give you the proper oil height with all the shock cambers full. Then it's simply using a fork measuring tool or syringe with a tube to a metal tube or ruler, siphon out a 100mm (baseline) to give you a 100mm air gap and away you go.
Depending on your riding conditions, a 5wt oil might be better then a 7.5 but it's hardly noticable ... more a PITA mixing a 5wt and 2.5wt to make a 7.5wt oil!!

 

[2premo]

Same as USD mate, to get the right oil height is the same procedure you would with USD except you are pumping the stantion as oppose to the body. The only key difference is that some conventional forks have bleed holes to the main body and some don't so the oil height can vary...best way, fill her to the top leaving a 5mm gap and pump the forks to bleed the air out, then at fully compressed, measure the oil height and this will give you the proper oil height with all the shock cambers full. Then it's simply using a fork measuring tool or syringe with a tube to a metal tube or ruler, siphon out a 100mm (baseline) to give you a 100mm air gap and away you go.
Depending on your riding conditions, a 5wt oil might be better then a 7.5 but it's hardly noticable ... more a PITA mixing a 5wt and 2.5wt to make a 7.5wt oil!!

to get 7.5 you mix 10 and 5, you knew that but were sleepy, oh wait other side of the world, you weren't a wake yet
relax, I'm making fun of a situation, you been riding this long you knew better

 

[ohmygewd]

to get 7.5 you mix 10 and 5, you knew that but were sleepy, oh wait other side of the world, you weren't a wake yet
relax, I'm making fun of a situation, you been riding this long you knew better

YAAAWWWNNNN...what was l dreaming !!

Apologies for the misinformation - had it backwards!!