Nomad Shock Oil Refill (With help from “Gadget”)

Many may find this page while searching for the procedure to refill their motorcycle shocks with new oil. This post refers to the Kawasaki Vulcan motorcycles, but other brands may be similar. I followed the procedure outlined at “Gadget’s” web page here. I’ve just posted a couple of notes here based on the experience I had that might be helpful to others that attempt this service.

In Gadget’s outline it is mentioned that a helper is needed to work the shock or add oil. Both have to be done at the same time, and a 2nd person is helpful. I got around this issue with my own “helper” pictured here.

Note the position of the shock. I found that by positioning at an angle similar to what it would naturally be while mounted on the bike, that I was less likely to spill any oil when refilling. Initially, I positioned it parallel to the ground and could not get all the oil in without losing some in that position. The Black and Decker Workmate table has a non marring clamp action. The white cup on the left is actually a collection cup that is part of my Mityvac system that I use to bleed brakes. It has graduated hash marks for measurement of the oil. I got about 110 ml out of each shock. I used the yellow bottle in the picture for filling the shocks with new oil.

The first shock took some time, as I spilled a little oil and had to start over. I soon realized that a catch pan under the shock as I filled it was helpful. If the pan is clean, the new oil that gets spilled can be re-used.

I used a paint roller pan as my catch pan. Here’s a picture of the oil that came out of one shock:

Use caution when taking the shock apart. Follow the warnings on Gadget’s page and don’t allow the shock to be pointed at you or anyone else when compressing the springs.

When you get to the part where you remove the retainer ring, snap ring pliers are real helpful even though there is no hole in the retainer ring as a snap ring would have. With a little patience, the ring is removed easily.

It doesn’t mention in Gadget’s site to extend the shock before reassembly. If the shock is compressed and you reinstall the valve, the shock will retract again by itself from the vacuum created when you extend it and will make it near impossible to extend to get the retainer back in place. You will then have to remove the valve again and possibly lose oil, requiring a refill all over again.

Good luck with this project and Happy Trails to you!!!