2004 CBF600 fork oil issue - trapped air ?

[colink98]

Hmmmm.

I have done this in the past but I seem to have a snag this time

the Haynes manual and the Honda service manual both say the same thing.

Fork Oil capacity of 440ml give or take.
then with the spring out and the fork fully compressed oil level should be approx 160mm from the top of the fork tube using a ruler.

its currently 100mm below the top of the tube and when i emptied the fresh oil into a jug there is slightly less than 400ml.

I suspect there is air trapped in the fork piston.
I have been pushing the fork tube up /down but very little air seems to have been released.
I did install new fork piston rings as per instructed.
and the only other means for air to escape is via the holes at the bottom of the fork piston.

Its the only explanation I can think of.
but I'm stuck as to what to do next.
____________________
PCX125 (stolen) - CBF600 (current)
Ride it like you stole it.
ride sensible and not like an idiot and you wont get 6 points in one week.

[Hong Kong Phooey]

Did you pump the damper rod too?
____________________
'81 CG125, '97 FZS600 : '99 CBR600F4, '09 KTM RC8

[colink98]

[sickpup]

There isn't really anywhere for an air bubble to hide so do you possibly have one pattern fork leg that has a slightly thicker wall so holds less oil?
You could even have a slightly different replacement fork leg, pretty sure those are 41mm OD which is very common so it could conceivably been replaced by something different by a previous owner of you haven't owned from new so check the chromey bits and the forks overall are the same length.

If it was me I would go by the air gap, fit and ride it and then take it off and recheck the air gap after a few miles but that is a bit of a bother.

As an aside YSS PD valves work very well in those forks and you can get preload adjuster fork tops for £20-£40 depending on where you order them from, Ebay UK or direct from China. Really improves the fork action and adds adjust-ability.

[colink98]