Removing fork

[Kwikasfuki]

Hi,

I need to get fork seals replaced. My local mechanic is fully booked up until November, but says he can fit me in if I can take off the forks and drop them off.

How easy/difficult is it? Remove guard, wheel, brakes, fairing cover below pinch bolts, undo pinch bolts and pull out forks? How much clearance from the floor is required to pull out the forks?

Is that it, or is there something else involved?

Thanks

[VirginiaJim]

I've done that.  It wasn't that difficult from what I recall but I had the service manual with me.  Biggest thing you can do for your mechanic is loosen the caps a bit before you take the forks off.  He'll thank you for that.

[Freddy]

Yeah, loosen the top clamp bolt, then the cap (put a bit of rag over it to minimise marring it), then the lower clamp bolt.

[maxtog]

https://zggtr.org/index.php?topic=8987.msg310785#msg310785

[Kwikasfuki]

Yeah, loosen the top clamp bolt, then the cap (put a bit of rag over it to minimise marring it), then the lower clamp bolt.

When you say loosen the cap, do you mean the bolt under the damping adjuster?

[Kwikasfuki]

https://zggtr.org/index.php?topic=8987.msg310785#msg310785

Tried the sealmate. Still leaking. With the amount of oil that's come out, I'd rather get it done properly.

[maxtog]

Tried the sealmate. Still leaking. With the amount of oil that's come out, I'd rather get it done properly.

I wasn't necessarily suggesting a seal cleaning device in your case, just pointing you to the post from one person who did remove their forks for repair.

I thought I remembered another thread about fork removal, and could not find it for some reason.

(Also, I discovered the Seal Doctor is much better than the Seal Mate).

[jwh20]

+1 on sealmates!

[Freddy]

When you say loosen the cap, do you mean the bolt under the damping adjuster?

Yes.

[lather]

I posted on a fork removal topic recently, probably on the COG site I have done this about 10 times. I find it worth the effort to unbolt the gorn and plastic "chin piece" to improve access to the lower pinch bolts. With the bike on center stand clearance is adequate for removal. Also even with pinch bolts fully loose the lower clam has a grip on the fork. I use a large flat blade screwdriver in the crack to lever it open just enough for the fork to slide right out.

[Kwikasfuki]

I posted on a fork removal topic recently, probably on the COG site I have done this about 10 times. I find it worth the effort to unbolt the gorn and plastic "chin piece" to improve access to the lower pinch bolts. With the bike on center stand clearance is adequate for removal. Also even with pinch bolts fully loose the lower clam has a grip on the fork. I use a large flat blade screwdriver in the crack to lever it open just enough for the fork to slide right out.

What's the gorn and plastic chin piece?

[Kwikasfuki]

Having the video on how to replace the seal, I'm tempted to do it myself.

I can fabricate the part to pull the spring to access the nut.

What I'm not sure about is the part used to prevent the spring sliding back down.

Also would need to fabricate something that would push the seal down. Maybe modify the seal doctor I have?

Decisions decisions ...

[gPink]

What's the gorn and plastic chin piece?

fat finger for horn?

[Kwikasfuki]

fat finger for horn?

Doh! I get it now. Blonde moment 😂

[maxtog]

fat finger for horn?

LOL!  I couldn't figure that out myself.  I kept thinking it was some new term I hadn't seen yet.

[Justcliff]

What's the gorn and plastic chin piece?

It's the flat plastic piece mounted to the bottom nose of fairing, directly under city lights. I don't know why anyone would try to work around it, way to easy to remove & opens up a lot of room.

[lather]

Sorry about the typo: should be horn.

[Kwikasfuki]

Right, removed forks.

The lower bracket I had to tease gently with a screwdriver and pull the forks to get them out. Putting them in will be a pain. I'm thinking maybe grease the bracket and forks when putting them back?

Also, are there torque settings for both the top and bottom pinch bolts?

Decided against charging seals myself. Letting my mechanic do them.

[Boomer]

Hi Asif, do not grease the forks when inserting them into the yokes (triple-trees).
If you do, one day you'll hit the brakes and the forks will punch up through the yokes and hit you in the face. 
Just clean the fork outers carefully and the same for the insides of the yokes.

[Kwikasfuki]

Hi Asif, do not grease the forks when inserting them into the yokes (triple-trees).
If you do, one day you'll hit the brakes and the forks will punch up through the yokes and hit you in the face.  :yikes:
Just clean the fork outers carefully and the same for the insides of the yokes.

Gulp, glad I asked! Thanks George, I'll make sure I just clean them