Front fork overhaul DIY

[Faber32]

Hi, I'm going to overhaul my front fork because of a bad oil leak from the top of the stem. Unfortunately in the service manual there's no indication of amount of fork oil and of torque specs. Do you know how to find this information? Did anyone already do the job for a People Gti?
Thank you

[CROSSBOLT]

Drain and measure the fork that is not leaking.

[Ruffus]

@Faber, (pls see pic) it's 177ml per side if completely drained.

[Faber32]

Thank you very much. I found a really bad leak on the top cap of the stem. When I compress the shock, it sprays oil all over the place! Probably the o-ring is gone. I'll go with 177cc of 20w oil.
@Ruffus: did you also find a guide on how to overhaul that particular stem?? Thanks a lot

[Ruffus]

@Faber, AFAIK are there two types of upper shock ends.
Pls see link...
https://www.kymcoforum.com/index.php?topic=30483.msg213236#msg213236

One is what you see in att. pics, the other one with a snap-ring to be taken out by pushing those top-plate a little bit down.
(@Iahawk did this with a pretty good ilustration). Pls use search.

Wheel, mudguard and front fairing have to go, then its simply taking off shocks and empty them by opening bottom plug and pumping a few times to be sure all old liquid is drained.

[Faber32]

Thank you very much! Mine is the one with snap ring and flat cap without the hex hole. I have only a doubt: many on youtube put the new seal on with a big socket, and then put the stem in place. Some say it's the wrong procedure and the seal must be put after the stem and driven with a fork seal driver.
I'm confused, do you know the right way? I'm also worried because I think a lot of debris went inside the shock, so now I'll have to clean all the parts very carefully

[Ruffus]

@Faber, IMHO there is no right or wrong way of doing that, here is how I do it:

-after taking apart, washing, cleaning and assambling the guidance cylinder and piston again
-I fix the shock in a vise, give the chrome piston a fine smear of fork oil, pull oilseals from top down to its seatings (no hurt of seal lips)
-take an U-shaped piece of a plastic pipe and hammer the seal into its seat
(still without oil fill)
-now I fill measured amount of fork oil
-recap with lid and snap ring

[Faber32]

Ok, thanks again I'll let you know after the job