2003 FLHR Fork Oil Level Problem
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Stage IV
Joined: Apr 2013
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From: San Diego, CA
2003 FLHR Fork Oil Level Problem
I'm working my way through the 20K mile service on my 2003 FLHR, and I've been stumped by changing the fork oil, of all things.
The manual I have states a 4.21" measurement from the top of the fork tube to the internal fork oil level. If I follow that spec, it takes something like 14oz of oil and the shocks are ridiculously stiff. Adding ~11oz like most other FLHR specs show gives a much more pleasant ride, but I'm nowhere near the recommended level measurement.
Has anybody encountered this before? Which should I follow?
The manual I have states a 4.21" measurement from the top of the fork tube to the internal fork oil level. If I follow that spec, it takes something like 14oz of oil and the shocks are ridiculously stiff. Adding ~11oz like most other FLHR specs show gives a much more pleasant ride, but I'm nowhere near the recommended level measurement.
Has anybody encountered this before? Which should I follow?
Outstanding HDF Member
Joined: Aug 2008
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I followed the oz spec on my 2006, then added about another 3/4 oz to each side to stiffen it up a bit. I'd say 14+oz is way too much. It's probably too late in your case, but I actually disassembled my front forks at 25k and was amazed at the funk in the forks. Metal, sludge, it was bad. I'm glad I did it when I did. It was a failure waiting to happen.
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Stage IV
Joined: Apr 2013
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From: San Diego, CA
I was doing it with the bike upright and the shocks uncompressed. I couldn't find anywhere that said which state they should be in when I took the measurement. I measured it with my 240lbs in the saddle as well, but it didn't change the measurement any.
Elite HDF Member
Joined: Sep 2007
Posts: 4,928
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From: Near Myrtle Beach, SC
Its a good idea to use something to check the height of the oil before you drain it out. Then you can replicate that level with the aid of the syringe level tool.
Some like to measure what comes out but that is not the accurate way to go about this service. But it is a shortcut.
Just remove the caps and use a dowell or a piece of small stiff wire to find your level. Then replace the oil to that level. Easy.
Some like to measure what comes out but that is not the accurate way to go about this service. But it is a shortcut.
Just remove the caps and use a dowell or a piece of small stiff wire to find your level. Then replace the oil to that level. Easy.
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Stage IV
Joined: Apr 2013
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From: San Diego, CA
Hindsight is 20/20. It's a little late for that now.
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Road Master
Joined: Jan 2012
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From: Maine
That's your problem. The measurement is with the forks compressed and no springs installed.
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Stage IV
Joined: Apr 2013
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From: San Diego, CA
Locking the front brake and rocking as much fork compression as I could gets the volume and height measurements to agree.
Just put it back together and did a test ride through every pothole in my neighborhood and it's perfect.
Thanks for all the advice. I don't know why Clymer's doesn't have at least a footnote letting you know the measurement should be done with the shocks compressed.
Now that I'm on here I'll be tracking these forums a lot more closely. A half dozen responses on a Sunday afternoon and my problems are solved in under two hours. You guys are great.
Just put it back together and did a test ride through every pothole in my neighborhood and it's perfect.
Thanks for all the advice. I don't know why Clymer's doesn't have at least a footnote letting you know the measurement should be done with the shocks compressed.
Now that I'm on here I'll be tracking these forums a lot more closely. A half dozen responses on a Sunday afternoon and my problems are solved in under two hours. You guys are great.
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