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"91- 1100 with the 41mm KYB. rebuilding w/Race Tech springs and Gold Valves. Instructions and local shops say springs have to be out to set oil. However, these arent like 750 forks, the cap does not unscrew enabling you to remove spring. Spring must be compressed in order to access holding bolt on dampening rod to remove cap. In other words, the entire damping rod assembly must be installed with spring. Anyone been through this before? Help?!!!

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just changed springs in my 97 forks which sound very similar to your 91 put the cartridge in with the damping rod, no spring, colapse down the tube and measure the oil level. If not consult a haynes manual for your forks hope this helps and dont forget to bleed the cartridge first to get the correct oil level. doug


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86 moded one end to the other
 

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yes you do have to have a spring compressor to get the nut off I made one with a block of aluminum about 1" thick with a hole the dia of the spacer tube cut it in half threaded bolts in to grab the holes in the spacer tube then used threaded rod down to a plate to put pressure on the bottom of fork works very well but took about 5 hours to build, curses, any way if these are cartridge forks you must get the spring off in order to bleed the cartride before you reassemble, this step is mandatory.

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86 moded one end to the other
 
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