Project 700ES

[posplayr]

That's how you do it, but there's no need to be gentle. It takes a bit of banging to get them out. The top fork bushing should come with them.

Depends if you are a whooze or not.

I damaged the bottoms of my forks with too many blows.

My Gixxer forks came apart easily after I cut back the rubber on the seals and allowed them to soak a couple of days with penetrating oil.

I'll be more careful next time

Joe,

Clamp the fork sliders in a vise and use the tubes as a slide hammer to pull the seals out. Be gentle but firm.........

Thanks,
Joe

That's how you do it, but there's no need to be gentle. It takes a bit of banging to get them out. The top fork bushing should come with them.

Joe,

Clamp the fork sliders in a vise and use the tubes as a slide hammer to pull the seals out. Be gentle but firm.........

Thanks,
Joe

Thanks Joe...I'll try it

[Joe Nardy]

I have the clips off, what is the trick to removing the seal?

Joe,

Clamp the fork sliders in a vise and use the tubes as a slide hammer to pull the seals out. Be gentle but firm.........

Thanks,
Joe

I have the clips off, what is the trick to removing the seal?

That is what I used. Can't be more than $5 for a 10ft stick at Homedepot or Lowes.

[renobruce]

I think I will take you up on the seal installation tool...sent you a PM

A piece of PVC (1 1/2 I think?) works really well....

The forks aren't indexed. They have a hole for the air and the collar the fits over them has a groove all the way around the inside to so that no matter what position the forks are in the hole isn't blocked. The collar is indexed to the top triple. There's a slot on the collar that fits in a tab on the top triple. You'll see it when you assemble them, it's hard to miss.

I broke down and bought the seal installation tool for the forks. If you need it let me know. It makes short work of those seals as they need to be driven in. It's also nice for installing the top bushing prior to the seals.

I think I will take you up on the seal installation tool...sent you a PM

Got them off, thanks tejasmud! I loosened the the clip-ons and they wiggled free...seals next!

That's cool. Reddirt mentioned it, I just echoed.

Got them off, thanks tejasmud! I loosened the the clip-ons and they wiggled free...seals next!

Got it ! I'll continue when I get home today.. I'm at work!!

Thanks guys!!

Joe,

Just under that air collar there is a metal spring clip, it is just a piece of spring wire bent into a C shape. You need to dig that clip out before the forks can be pulled down and out. Once you have this clip out, the forks will pull down and out just like any other fork. There is no need to remove the risers, or fork cap.

Not technically, but in the real world ... I've got a beer that says that's his problem.

At least loosen them up where they bolt to the top clamp. It might help.

Mine were frozen to the forks like I never would have imagined. I had to tighten down the triples again and work the risers back and forth using penetrating oil to get them off. There's not much clearance and all of the elements can get in there and cause problems.

When they were off I took some sandpaper and cleaned up the inside surface and the went back on nice and easy.

[Nessism]

Joe,

Just under that air collar there is a metal spring clip, it is just a piece of spring wire bent into a C shape. You need to dig that clip out before the forks can be pulled down and out. Once you have this clip out, the forks will pull down and out just like any other fork. There is no need to remove the risers, or fork cap, just unbolt the pinch bolts and the fork tube will pull down.

At least loosen them up where they bolt to the top clamp. It might help.