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Can the forks be removed without removing the fairing ?

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  • Yamaha Master
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Hi, Puggy309 I would love to help you but I can't believe the batteries in my crystal ball are dead and my mental telepathy headset is broken. I need the year, make, and model of your motorcycle please provide this information in the comment section below. Good luck and have a nice day.

Posted on Oct 17, 2016

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Posted on Jan 02, 2017

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SOURCE: How do I remove the false gas tank on a 1984 honda goldwing

You can pick up a complete owners/service manual as well as the parts manual on cd. I got mine for my GL1100, then when I upgraded to my GL1200, I picked up another set from the same person.
Contact Wanda G at wickedinaz@cox.net. I believe she still sells the cd's for around $7.00 including the shipping anywhere in the US.
When I got mine, she included both the owners/service manual and the parts manual. Pretty big to download, at around 200mb.
Manuals are good enough, I just rebuilt my engine, and all 4 carbs and I'm no mechanic.

Posted on Apr 05, 2009

  • 478 Answers

SOURCE: Adding Fork Oil

yes see caps at top of trees caps come off at the bottom of shocks you will find a single think 9 mm bolt to drain oil out. Make sure you drain all the oil up and add the same amount that shocks are required nothing more nore less.....

Posted on Feb 10, 2010

  • 8909 Answers

SOURCE: I've got slight oil seepage coming from under the

Unfortunately there is no "home cure" and it will only get worse.
To support the bike, use two straps, ( the type used for strapping down loads on the back of pickup and flat bed vans). strap around the frame at the front under the tank and use plenty of soft cloth wadding, old sheets etc, to stop any paintwork damage. Tie the straps to a roof timber with at least a 45degree angle, like the letter Y with the top parts of the Y tied to the roof member and the base of the Y is your bike. It is a good idea to have the rear wheel in a paddock stand.

Posted on Feb 12, 2011

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1 Answer

How to remove front forks from a 1992 honda fireblade


Probably do-able but you will have to make sure you can support the bike from under the engine. Some bikes will allow this all depends on what is below the oil sump area. If you can support the bike from under the engine I would suggest getting an ABBA stand and a small car jack. With the front wheel raised remove front wheel, fork brace if fitted, mudguard and brake calipers ( I always hang the calipers on string tied to the handle bars. You will have to remove anything that is fixed to the fork sliders i.e. cable clamps, brake line unions and fixing bolts speedo cable clamps etc etc. Undo the top and bottom yoke clamp bolts the forks should then be able to be gently twisted out. Be very careful when twisting the fork legs as the yokes are quite hard metal and can easily score the chrome plating. Hope this helps

Jun 04, 2014 | 1992 Honda CBR 900 RR Fireblade

1 Answer

1993 electra glide front faring removal


1993/1994 Outer Fairing and Windshield for FLHTC, and FLHTC ULTRA

Removal

First remove the headlight assembly and the bolts, nut and the washers attaching the outer fairing piece to the windshield and inner fairing piece. THEN loosen the four bolts attaching the light bracket and the outer fairing piece to the fork brackets. Remove the upper bolts but leave the lower ones in place. Cover the fender. THEN rest the lower light bracket onto the fender. THEN remove the fastener securing the headlamp trim ring and remove the trim ring. THEN remove five screws that secure then headlamp assembly to the outer fairing and remove the headlamp assembly. THEN reach through the headlamp opening and loosen four locknuts on the two studs on each side of the headlight area which attach the fairing to the metal brackets inside the fairing. THEN remove the fairing by pulling it straight ahead away from the brackets.

Installation

First loosely position the outer fairing in place over the inner faring with the four studs going into the two brackets. Then install the five windshield fasteners through the outer fairing, the windshield and the inner fairing. THEN tighten the four stud nuts to secure the fairing to the brackets, being sure to have the inner and the outer fairing properly aligned at their outside edges. THEN position the light bracket so that the slots fit around the upper fork bracket bolts and thenalign the lower fork bracket mounting holes and replace the two lowering fairing mounting bolts through the light bracket and the outer fairing and the inner fairing and screw them into the lower fork bracket. THEN make sure that the rubber seal around the inner fairing is properly seated and not pinched and tighten the four fairing attachment bolts to 12-13 foot pounds (16 -19 Nm). THEN tighten the windshield screws to 4 inch pounds (0.45 Nm) but no more than this amount starting in the middle and working outwards on both sides. THEN reinstall the headlight assembly.

Jun 03, 2014 | Harley Davidson FLHTCUI Electra Glide...

1 Answer

How do i rebuild 41mm forks


Depends on how much rebuilding you want to do.
See below:

FRONT FORK 2.16
CHANGING FORK OIL On a 2010 Touring Motorcycle 41 mm Fork
If only replacing the fork oil remove the for, clamp a fork holder tool in a vise in a horizontal position and with the fork cap bolt topside securely clamp the fork into the tool, remove the fork cap bolt, remove and discard the quad ring seal, carefully remove the fork tube plug from the fork tube and because it is under strong spring pressure have and maintain a firm grasp on the plug as the last thread is turned because it will want to fly upwards under the spring pressure, remove and discard the O-ring fork tube plug o-ring, remove the fork spring from the fork tube, remove the fork assembly from the fork tube holder tool, being aware that the damper valve if one is installed (All touring models, with the exception of Road King, have a damper valve type fork on both the left and right sides. Road King uses the conventional type fork on both sides.) will fall out when the fork tube is inverted for draining turn the fork upside down and drain the fork oil into a suitable drain pan while slowly pumping the fork tube and slider at least ten times and then allow about 10-15 minutes for the fork assembly to completely drain. THEN with the fork tube right-side-up securely clamp the fork slider (not the fork tube) into the fork tube holder, install the drain plug at the bottom of the fork slider, if it had been removed and tighten the plug to 72-96 in-lbs (8-11 Nm).

MODEL FORK TYPE AMOUNT
OZ. ML IN. MM
All models Damper Valve 10.7 317 4.92 125
Except FLHR/C
FLHR/C Conventional 11.0 325 4.92 125

Pour slightly more Harley-Davidson Type E Fork Oil directly into the fork tube than is specified for the fork type, slowly pump the fork tube until some resistance is felt and then pump a few more times and then for all models except FLHR/C (i.e. for damper valve type forks), install a new wear ring in its groove in the damper valve, with the wear ring at the bottom (spring side up) slide the damper valve into the fork tube, install the fork spring into the fork tube, use the fork spring to push the damper valve to the bottom of the fork tube, remove the fork spring from the fork tube, slowly pump the fork tube a few more times to eliminate air from the damper valve, adjust the ring of a fork level gauge 4.92 inches or 125mm and then with the fork tube bottomed in the fork slider insert the tube of the gauge into the fork slider until the metal ring rests flat on the top of the fork tube and use the gauge plunger to draw oil from fork (if no oil is drawn out, add a small amount to the fork tube and repeat the process) until the oil level is at the specified level in the fork slider, install the fork spring into the fork tube with the tighter wound coils at the bottom, remove the fork slider from the fork tube holder tool, clamp fork tube into the fork tube holder tool, install a newO-ring onto the fork tube plug, install the fork tube plug into the fork tube and tighten it to 60-70 ft-lbs (81.4-94.9 Nm), install a newquad ring seal onto the fork cap bolt and install it into the fork tube plug to prevent loss of fork oil while working further with it. THEN on right side fork, loosely install the axle holder with its flat
washers, lockwashers and nuts, install the fork and assemble the motorcycle.

To remove a 2010 Touring 41 mm fork assembly FIRSTraise the front wheel, remove the front wheel, remove the front fender, and for FLHR/C remove the headlamp nacelle. And for FLHX, FLHT/C/U, FLHTK remove inner fairing cap, and for FLTRX remove the instrument nacelle, loosen the fork cap bolt, but do not
remove it at this time, loosen the pinch bolt but do not remove it, hold the fork slider to prevent the fork from dropping, remove the fork cap bolt from the fork tube plug, slide the fork tube down to remove. And loosely install the fork cap bolt to prevent loss of fork oil while working with the fork.

DISASSEMBLY
To disassemble a 2010 Touring 41mm fork assembly FIRST remove the fork assembly, the right side fork remove the axle holder from the end of the fork slider, drain the fork, install the fork spring into the fork tube, place a shop cloth or towel on the floor, turn the fork assembly upside down, press the end of the spring against the shop cloth or towel to prevent rotation of the damper tube and remove the metric screw from the end of the fork slider with an air impact wrench, discard the screw and copper washer, remove the fork spring, the damper valve (if equipped) and the damper tube from the fork tube, remove the wear ring and rebound spring from the damper tube, remove the wear ring from the damper valve, (if equipped), remove the retaining clip using an appropriate pick tool, remove the fork tube from the fork slider by using the fork tube as a slide hammer tool, slide the fork oil seal, the slider spacer and the slider bushing off from the end of the fork tube, discard the fork oil seal and the slider bushing, gently pry at the split line to expand the fork leg bushing and remove it from its groove at the end of the fork tube, discard the fork leg bushing and remove the lower stop from fork the slider.

CLEANING AND INSPECTION
Thoroughly clean and inspect all parts and replace any parts that are corroded, bent, inoperative or otherwise obviously damaged, inspect the fork cap bolt quad ring seal and the fork tube plug o-ring for cuts, tears or signs of deterioration and replace if and as necessary, replace the retaining clip if is bent or distorted, check the slider and the fork leg bushings for scratches or excessive wear and always replace bushings in a set if either bushing needs to be replaced, check both the fork tube and the fork slider for scoring, scratches and excessive or abnormal wear and replace parts if and as required, set the fork tube on V-blocks and measure its runout using a dial indicator gauge and replace it if the runout exceeds 0.008 in. (0.2 mm), inspect the upper fork spring and the rebound spring for damage or distortion, and replace the upper fork spring if its free length is less than19.27 in. (489.4 mm) for Non-Fairing Models and 18.73 in. (475.7 mm) for Fairing Models and replace the rebound spring if its free length is less than 0.938 in. (23.8 mm) or any time the upper fork spring is replaced.

ASSEMBLY
To assemble a 2010 Touring 41 mm fork assembly FIRST coat the ID of the fork leg bushing with clean fork oil, expand the fork leg bushing at the split line only enough to slip it over the end of the fork tube and into its groove on the fork tube, install a newwear ring into the groove at the top of the damper tube, install the rebound spring on the opposite end, with the wear ring topside slide the damper tube into the fork tube so that the tube end drops through the hole at the bottom of the fork tube, install the lower stop at the end of the damper tube, install the fork slider into the fork tube holder tool, slide the fork tube into the fork slider, coat the ID of the slider bushing with clean fork oil, slide the slider bushing down the fork tube, slide a 41 mm fork seal installer tool down the fork tube and using the it as a slide hammer drive the slider bushing into the counterbore of the fork slider, then remove the tool, place masking tape over edge of the fork tube to avoid damaging the lip of the fork oil seal during installation, coat the ID ofa new fork oil seal with clean new fork oil, then with the lip garter spring side facing down toward the fork slider slide the seal down the fork tube until it contacts the slider spacer, remove the masking tape from the edge of the fork tube and using the 41 mm fork seal installer tool as a slide hammer, drive the fork oil seal down the fork tube until the retaining clip groove is visible above the seal in the ID of the fork slider, remove the tool, install the retaining clip in the groove, install the fork spring into fork the fork tube, remove the fork assembly from the fork tube holder tool, place a shop cloth or towel on the floor, turn the fork assembly upside down and press the end of the spring against the shop cloth or towel to prevent rotation of the damper tube, install a new screw and a new copper washer at the bottom of the fork slider and while compressing the spring tighten the screw to 132-216 in lbs(14.9-24.4 Nm), remove the fork spring from the fork tube, fill the fork with fork oil to the specified amount and complete assembly of the fork. On the right side fork, loosely install the axle holder with its flat
washers, lockwashers and nuts.

INSTALLATION
To install a 2010 Touring 41 mm fork assembly FIRST remove the fork cap bolt, slide the fork tube up and into the slider cover, lower the fork bracket, the fork stop, and the upper fork bracket, install the fork cap bolt, install the pinch bolt and lockwasher into the lower fork bracket and tighten the pinch bolt to 53-57 ft-lbs(71.9-77.3 Nm), tighten the fork cap bolt to 60-70 ft-lbs (81.4-94.9 Nm) and repeat these steps on the other fork, install the front fender and wheel, and for FLHR/C install the headlamp nacelle, for FLHX, FLHT/C/U, FLHTK install the fairing inner cap and for FLTRX install the instrument nacelle.

May 15, 2014 | 2010 Harley Davidson FLHX Street Glide

1 Answer

Forks knocking


are you sure it is the forks, I have a 99 and it clunks like hell and it is the fairings the forks are fine, if you remove the fairings and try it again if you can.

Apr 22, 2014 | 2006 Suzuki GSX 1300 R Hayabusa

1 Answer

Fork lock locked up won't unlock


I don't know if this will help. It was sent to me by a friend of mine and I've never tried the procedure. I do not work on these ignition switches and fork locks. This is for a newer model but it may help. Good Luck. Steve

Here's the procedure to remove the IGNITION /LIGHT KEY SWITCH AND FORK LOCK for a 2005 FLHT/C/U or FLTR (Domestic): Tools needed for removing ignition switch A T27 Torx, a small flat blade screwdriver, 7/8 wrench.

1. Remove the outer fairing and windshield

2. To remove the ignition switch, insert the ignition switch key and turn to the UNLOCK position. Leaving the key installed, rotate the knob to ACCESS. Depressing the release button at bottom (left side) with a small screwdriver, push key down and turn an additional 60 degrees in a counter-clockwise direction. Lift and remove knob.

3. Using a 7/8 wrench on flats, loosen switch nut and remove from threaded post of ignition switch housing. Remove collar and spacer.

4. Using a T27 TORX drive head, remove the two screws (with flat washers) that secure fairing cap to left and right sides of fairing.

5. Remove the switch position plate by pulling tabs from slots in faring cap. If necessary, raise the fairing cap slightly to facilitate removal.

6. With the forks turned fully to the left, disconnect the Fairing cap switch connector (105) 12-place Multilock (black), from behind right side of fairing cap. Depress the button on the plus side of the connector to pull apart the pin and socket halves.

7. Remove the fairing cap from the motorcycle.

8. Locate the ignition switch connector (33), 4-place Packard, at bottom of radio. Slide connector off anchor and separate pin and socket halves.
9. Remove the socket screws (with flat washers) and lift the switch housing from the upper fork bracket bore. Route the ignition switch connector to rear of inner fairing and remove switch housing from the vehicle.

Sep 19, 2011 | 2000 Harley Davidson FLHTCUI Electra Glide...

1 Answer

Flhtcui key switch install, new out of the box


I've posted this before. I got this from a friend of mine and like I said before, I cannot attest to it's accuracy. I do not work on these types of ignition switchs. In the past, they required a special tool to align the switch that I didn't have. Anyway, this is what I have on the switch. I hope it works for you.

Good Luck
Steve

Here's the procedure to remove the IGNITION /LIGHT KEY SWITCH AND FORK LOCK for a 2005 FLHT/C/U or FLTR (Domestic): Tools needed for removing ignition switch A T27 Torx, a small flat blade screwdriver, 7/8 wrench.

1. Remove the outer fairing and windshield

2. To remove the ignition switch, insert the ignition switch key and turn to the UNLOCK position. Leaving the key installed, rotate the knob to ACCESS. Depressing the release button at bottom (left side) with a small screwdriver, push key down and turn an additional 60 degrees in a counter-clockwise direction. Lift and remove knob.

3. Using a 7/8 wrench on flats, loosen switch nut and remove from threaded post of ignition switch housing. Remove collar and spacer.

4. Using a T27 TORX drive head, remove the two screws (with flat washers) that secure fairing cap to left and right sides of fairing.

5. Remove the switch position plate by pulling tabs from slots in faring cap. If necessary, raise the fairing cap slightly to facilitate removal.

6. With the forks turned fully to the left, disconnect the Fairing cap switch connector (105) 12-place Multilock (black), from behind right side of fairing cap. Depress the button on the plus side of the connector to pull apart the pin and socket halves.

7. Remove the fairing cap from the motorcycle.

8. Locate the ignition switch connector (33), 4-place Packard, at bottom of radio. Slide connector off anchor and separate pin and socket halves.

9. Remove the socket screws (with flat washers) and lift the switch housing from the upper fork bracket bore. Route the ignition switch connector to rear of inner fairing and remove switch housing from the vehicle.

Sep 18, 2011 | 2005 Harley Davidson FLHTCUI Electra Glide...

1 Answer

2005 FLHTCUI key switch replacement. Mitchell's Harley Davidson wrecked my bike. Last thing they did before I took it back was break the key switch.


I can't swear to the accuracy of these instructions as I don't mess with the later Twin Cam bikes. I work on the older Shoveheads, Panheads, and Ironhead Sportsters that the dealers won't work on. But, a friend sent this to me. Maybe it works. Good Luck.

Here's the procedure to remove the IGNITION /LIGHT KEY SWITCH AND FORK LOCK for a 2005 FLHT/C/U or FLTR (Domestic): Tools needed for removing ignition switch A T27 Torx, a small flat blade screwdriver, 7/8 wrench.

1. Remove the outer fairing and windshield

2. To remove the ignition switch, insert the ignition switch key and turn to the UNLOCK position. Leaving the key installed, rotate the knob to ACCESS. Depressing the release button at bottom (left side) with a small screwdriver, push key down and turn an additional 60 degrees in a counter-clockwise direction. Lift and remove knob.

3. Using a 7/8 wrench on flats, loosen switch nut and remove from threaded post of ignition switch housing. Remove collar and spacer.

4. Using a T27 TORX drive head, remove the two screws (with flat washers) that secure fairing cap to left and right sides of fairing.

5. Remove the switch position plate by pulling tabs from slots in faring cap. If necessary, raise the fairing cap slightly to facilitate removal.

6. With the forks turned fully to the left, disconnect the Fairing cap switch connector (105) 12-place Multilock (black), from behind right side of fairing cap. Depress the button on the plus side of the connector to pull apart the pin and socket halves.

7. Remove the fairing cap from the motorcycle.

8. Locate the ignition switch connector (33), 4-place Packard, at bottom of radio. Slide connector off anchor and separate pin and socket halves.
9. Remove the socket screws (with flat washers) and lift the switch housing from the upper fork bracket bore. Route the ignition switch connector to rear of inner fairing and remove switch housing from the vehicle.

Sep 03, 2011 | Harley Davidson FLHTCUI Electra Glide...

1 Answer

How to remove ignition switch on 2001 electra-glide


Here is something a friend sent to me. I've never taken one of these switches out so I can't say for sure if this is correct but it's all I have.

Here's the procedure to remove the IGNITION /LIGHT KEY SWITCH AND FORK LOCK for a 2005 FLHT/C/U or FLTR (Domestic): Tools needed for removing ignition switch A T27 Torx, a small flat blade screwdriver, 7/8 wrench.

1. Remove the outer fairing and windshield

2. To remove the ignition switch, insert the ignition switch key and turn to the UNLOCK position. Leaving the key installed, rotate the knob to ACCESS. Depressing the release button at bottom (left side) with a small screwdriver, push key down and turn an additional 60 degrees in a counter-clockwise direction. Lift and remove knob.

3. Using a 7/8 wrench on flats, loosen switch nut and remove from threaded post of ignition switch housing. Remove collar and spacer.

4. Using a T27 TORX drive head, remove the two screws (with flat washers) that secure fairing cap to left and right sides of fairing.

5. Remove the switch position plate by pulling tabs from slots in faring cap. If necessary, raise the fairing cap slightly to facilitate removal.

6. With the forks turned fully to the left, disconnect the Fairing cap switch connector (105) 12-place Multilock (black), from behind right side of fairing cap. Depress the button on the plus side of the connector to pull apart the pin and socket halves.

7. Remove the fairing cap from the motorcycle.

8. Locate the ignition switch connector (33), 4-place Packard, at bottom of radio. Slide connector off anchor and separate pin and socket halves.

9. Remove the socket screws (with flat washers) and lift the switch housing from the upper fork bracket bore. Route the ignition switch connector to rear of inner fairing and remove switch housing from the vehicle.

Sep 03, 2011 | 2001 Harley Davidson FLHTCUI Electra Glide...

2 Answers

How easy is it to replace my fork seals on my 1993/4 900 trophy?


I found it easier to remove the forks and take them to a shop to have the seals done.In doing this you are still saving a bucket load of money. Removal of the forks takes about an hour and a half and is relatively easy without any specialist tools. You only have to remove the top part of the fairing.

May 10, 2011 | 1994 Triumph Trophy 900

1 Answer

How do i remove the outter fairing ?


There are 2 more on the other side beneath the inner fairing,to the inside of the front fork downtubes

Oct 13, 2009 | 2004 Harley Davidson FLHT - FLHTI Electra...

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