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Fork Cap Removal

  • Thread starter Thread starter ColinClayton
  • Start date Start date
C

ColinClayton

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I feel like this is really easy but i can't figure out how to remove the end caps on the forks of my bike to add oil. Its an 83 GS 550L, heres a picture.
 

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Uncrew the center core..theres an oring under it that seals the oil from seeping back and will most likely need replaced as well. But first, set a pan under the lower fork and axle and open the drains but taking out the screws there...release any air first from the nipple up above.... if so equipped.

Now get on the bike and stand on the front pegs ( bike on center stand ) and gently rock forward to pump the forks a little. This will pump more oil out quicker than just letting them drip. Once your satisfied they are sufficiently drained, replace the drain screws and fill from the top with specified amounts of oil. I have a small measuring cup in ounces Im use for measuring the oil.
 
If you get to taking the entire top parts off, get a board and jack under the engine and lift the front tire just off the ground. This takes the compression out of the springs so the parts dont go flying as you remove them.
 
And, whatever you do, don't have the bike on the sidestand when you remove the tops.
Some idiot did that, just the once...
:stupid:
 
I believe these are the ones where you need to contrive to push down on the fork cap, then remove the retaining ring down in there.

It takes about 3.5 hands, so you might have to take your shoes off or recruit a helper.
 
bwringer said:
I believe these are the ones where you need to contrive to push down on the fork cap, then remove the retaining ring down in there.

It takes about 3.5 hands, so you might have to take your shoes off or recruit a helper.
Click to expand...
Yeah that's what it looks like to me to.My 81 650E had those,what a PITA they are to get in or out.
 
If you need to remove the cap first remove the air valve because it'll be in the way then find something that you can center on the air valve hole without damaging the threads and you can push on. Push the cap down a bit and with something sharp like an o-ring pick get under the clip and pull it out. I find it easier to do this from the end opposite the gap in the clip and it should just pull right out. Make sure the bike is supported under the engine and there is no weight on the front wheel or you'll be picking yourself up from under the bike when you remove the second cap. Don't ask how I know!!!
 
For a simple oil change ( not full on tear down ) is why i suggested just remove he air valve and get new orings. Small funnel and pour oil thru the hole..done. No worries about getting teeth blown out of your face etc etc etc.
 
chuck hahn said:
For a simple oil change ( not full on tear down ) is why i suggested just remove he air valve and get new orings. Small funnel and pour oil thru the hole..done. No worries about getting teeth blown out of your face etc etc etc.
Click to expand...
Definitely if that's all that's all that needs doing.
 
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