Phase 3 complete. Forks out, drained and all apart. Time for a hot one. Coffee and a slice of last nights pizza.
Observations are: Now that I them all apart it looks like external top out spring. Now that I see it apart and look at the diagram again, its clear what is shown and I was reading it wrong. Bushings look real good. I am betting the previous owner had these serviced not too long ago and/or at least some point in the past. The oil in the cartridge side looked really good. Hard to believe this is 12 years old and 60K. The damping rod side not so much, but the it always looks like crap even after a few months. Its all going back together with the new stuff.
I could not get the 6mm bolts loose when in the bike. When trying to break loose not only does the steering stem want to turn, but so does the lower fork tube. The whole thing always wants to rotate and I was not able to hold with one hand and work the wrench with the other. Not very good at using my feet. -- So loosened the upper clamps, loosen the caps, and remove the forks. -- I put them in my bench and let that hold and support the lower tube while I broke loose the 6mm bolts. At that point I should have left the just barely broke loose, removed the caps and pour out the fluid from the top as it says in the Honda manual. Pump them to get out as much as possible, bla bla bla. Now finish disassembly. -- What I did was try to remove the 6mm bolts and let it drain out the bottom and pump them to get most out, etc. Then remove cap and disassemble. On the damping rod side it work ok except for a little splash as the fluid came gushing out. Like it really wanted out of there. However on the cartridge side I remove the 6mm bolt but you also need to loosen the cap to raise the cartridge enough to allow the fluid to drain. Not thinking I held the fork horizontal and removed the cap. Fluid can pouring out. My drain pan was covering the other end. Ooops. Fortunately I was outside in the drive way and not in the garage. The rain will wash it to night. SO DONT DO IT LIKE THAT.
Off to Home Depot for some cleaning supplies.
So far so good. It probably took longer to sit here and sip coffee and type this than it did to get it all apart, take pictures and all that.
2005 GL1800ABS 62,000mi
2003 ZG1000 134,000mi