Forum

[ChrisD]

Hi Guys


I am trying
to rem ove the fork main tubes from my 1996 500cc Classic preparatory to
fitting gaiters.  The main tube will not
unscrew.  I have used an M8 bolt with
head fitted to the ½“ hex socket but the bolt sheared. .



 As I understand it the main tube needs to be
taken off only to remove the shroud.  If
so, why can I not cut it off with my dremel (see attached 2 images in photobucket).  Then I could directly fit the gaiters.  I have no other problem with the uppers of the
fork so why force the main tubes off now and risk damaging the threads in the
casquette?


I am also
fitting our hosts softer progressive springs. 
As I understand it, I do not need to remove the main tubes in order to
change out the spring.  If this is
correct, then the main tube can stay put until the day I really must force it
off and then I’ll risk the consequences. 



Your
comments would be very welcome!


Cheers,
ChrisD. (photobucket


PS cannot
remember how to make a sub-album so the three pictures mentioned above are in
the main album.

[1950s Bulleteer]

It is possible to exert more force to turn the fork tubes by using the hexagonal bar that holds the footrests. This is exactly the right size for the job, you can insert about half the length into the top of the fork tube and use two ring spanners on the protruding hexagonal length to gain a "T-Bar" effect. Best to put a nut and washer on the end, like you did when using the 8mm bolt, to stop it accidentally slipping down into the tube. You need to get the ring spanners onto the hex before inserting as they won't go over the nut and washer.

[John J]

Hi Chris, I fitted gaitors without removing the stauntions. I put masking tape around the fork cover about 1 inch down from the clamp slot. I then carefully cuy the tube off with a junior hacksaw. Touched-up the bare cut and fitted the gaitors. The gaitor was a nice snug fit in the cover tube giving a good finish to the job. 

[PeteF]

I'm assuming you have loosened the pinch bolt in the bottom shroud.


I just got a piece of 1/2" hex bar off Ebay and used that. Just a bit easier than stripping out the footrest rod.


You could just cut them off as you say, but read John J's post - shortened shrouds would trim the top of your gaiters nicely. (in fact Mr H sells short shrouds for just this purpose)


Why didn't I think of that John?

[ChrisD]

Guys, thanks for the replies.  I have a half-inch allen key and found that either with slow heavy pressure over 60ft-lb ('cos I used a torque wrench) or fast hit with a 2lb hammer did not break the main tube free from the casquette threads (yes, I am turning the allenkey clockwise to unscrew).  I suspect the aluminium has welded itself together and forcing it off will break something.  But I am happy to have it confirmed that I do not need to get the main tubes off to fit gaiters and as my images show, I shall therefore cut the shrouds.  If I do it carefully, they can be re-used (I bought our hosts shortie shrouds as well as the gaiters).


Its never easy, is it.


ChrisD

[Dennis C]

Hi Chris


Just a thought, don't forget that when unscrewing the stanchions they unscrew from underneath and from above you turn them clockwise.

[ChrisD]

Hi Guys,
well I finished the forks on my 1996 500cc Classic. 


Clamped the
forks down tight with luggage straps then a heavy hammer and high speed whack
on the slider stud cap nuts had them loose very quickly.


Cut off the
shrouds exactly as shown in my photobucket (Chrisd200), similarly cut the new shortie
shrouds because I couldn’t get the main tubes off  (as I wasn’t prepared to risk the excessive
force I’d need to get them unscrewed, yes clockwise from the top, even with the
correct 12,5mm allen key). 


Fitted our
hosts new softer springs to make the ride easier.  But inside the forks were – old softer
springs!  With the same progressive
portion at the base and the same coil spacing throughout - and I have owned the
bike since 18,5km so who did this?  Anyway
they had collapsed a centimetre or so so they needed some changing. 


Then………..I
had forgotten to tighten the straps holding the bike on the bike lift and it
fell off! @#$%^&.        NO DAMAGE!  How lucky is that?


Fitted the
gaiters.  Janet, wherever you are, you
wrote in Bulletmania in ~2006/7 how to fit the gaiters over the slider
tubes.  Excellent, it took less than a
minute to do once I’d cut the plastic strip. 
They didn’t need oiling or warming (although its ~30degC here in Cape
Town) just worked on easily.  I couldn’t
believe how easy it was.


Once I’ve
filled the forks with ~250ml ATF I shall be away again.


Cheers,
ChrisD