SETTING OIL LEVEL
ON KYB AND WP UPSIDE-DOWN FORKS 
(when oil level is given in mm)

On open-chamber upside-down forks there is a gap between the inner and outer fork tubes (between the fork bushings). 

Two types of forks:

1. Has Equalizing Hole
Showa forks have an Equalizing Hole.

2. No Equalizing Hole
On most KYB and WP forks there is no Equalizing Hole in the inner (chrome) fork tube.
Without this hole, the problem is not knowing how much fork oil is actually in this area.

This must be considered when oil level is given as a distance (mm) instead of a volume (cc).

To set the oil level correctly using our method you must remove all oil in this area. 

Note: We developed this method in 1989. This problem was not addressed in any Service Manual until the year 2000. Kawasaki started using a method where they completely filled this area instead of emptying it (go figure). This means their method and our method will be different by about 40mm - oops! All our suggested oil levels use our method of evacuating this area.

 

BLEED THE CARTRIDGE AND SET THE OIL LEVEL
A28- Invert the fork and pour oil into the top of the fork. Stroke the damping rod to bleed the cartridge. Continue to stroke until all bubbles in the cartridge are gone and it strokes smoothly and evenly.
You can speed up the process of filling the cartridge by placing your hand over the open end of the upper fork tube while the fork is extended and pressing downward on the fork. The increase in pressure will quickly force the oil into the lower cartridge.

A29- Set the Oil Level Tool (TFOL 02) to the correct level according to the DVS.

A30- Extend the outer fork tube all the way until it stops. This will remove oil from this area and dump it into the main chamber.

A31- Bottom the Outer Fork Tube as well as the Damping Rod. To set the oil level suck out the excess oil with the Oil Level Tool.
Repeat by extending the Outer Tube all the way, collapsing it and sucking out the excess.
Done!