Stumped! GS450 Front fork top cap...

[driftingpanda]

Hey guys/gals,

First off, I want to say thank you to everyone on this board. It's been such a resourceful site for a total newbie like me. This is my first ever motorcycle project, and it's been a heap of fun so far!

I did do a search here, I have a Clymer's manual, but I'm pretty stumped on this one.

I have a 1980 GS450 (L model... I think), and I'm rebuilding the front forks with new seals and boots. Instead of a top fork cap with a hex head like I've seen everywhere, I seem to have some kind of a block-off plate with an air valve on it. The plate is held in by an embedded c-clip (non-removable), and the plate itself does not screw out. I did manage to get the air valve off with an impact, but still have no idea as to how to remove it to get to the springs.

Any help would be appreciated!

-danny

Here's a picture of my predicament.

[Steve]

First of all,

Impressive, picture on the first post, too.

What makes you think that the "embedded c-clip" can't be removed? It had to go in somehow.

I think that if you remove the clip, it will come apart.
One thing to watch, though, is that the c-clip might be the only thing keeping tension on the springs.
Remove the clip and things MIGHT go S P R O I N G ! ! !

.

[driftingpanda]

Hey Steve,

Yes, I'm also a member of a few other automotive forums, I fully comprehend the importance of pictorial illustrations!

I say the c-clip is non-removable because it sits inside a grove in the fork tube, and also a groove in the "block off plate" as well. The clip is more like a c-ring, about the thickness of a paperclip. I can't even reach it with another paper clip, let alone pull it out of the groove. I even thought about pushing the plate down into the tube, turning it sideways, and slipping it out through the cut-out on the c-ring, but it doesn't want to pop down, either.

Here's a close-up of the darn thing.

[bonanzadave]

I bet you can push it down. Mine were corroded like that so after soaking it with deep creep I put a deep socket on the plate and gave it a few raps. Boooing ! Keep in mind mine had a threaded cap with no clip like you speak of. Whats the other side look like ?

[Turtle]

Push it down, hold it down and remove the c clip and the lot will come out

[driftingpanda]

Apparently, this IS supposed to serve the purpose of the threaded cap. There was nothing else on top of this besides the finishing rubber cap. The bottom looks like a normal GS fork, with the allen hex thing that holds the damper rod thing.

I'll give it another try with the mallet. Any other ideas?

[driftingpanda]

Push it down, hold it down and remove the c clip and the lot will come out

Awesometown. Gonna go try it now. Thanks!

[bwringer]

Push it down, hold it down and remove the c clip and the lot will come out

Yup! It takes three and a half hands, but this is how it comes out.

[chef1366]

I am so glad this was posted. I'm about to rebuild the forks on an 86 GS450 with the same type fork cap. Now I know I need a couple of extra hands.
Thanks

[Steve]

Now I know I need a couple of extra hands.

Or just a vise with e x t r a - w i d e opening.

You have a hydraulic press? Squeeze the air cap down using a deep socket that is slim enough to still allow you to get to the clip, then release the pressure.
.

[driftingpanda]

I am so glad this was posted. I'm about to rebuild the forks on an 86 GS450 with the same type fork cap. Now I know I need a couple of extra hands.
Thanks

Thanks everyone for the helpful tips!

Yes, it took two of us to get the thing off. Mine was rusty and had to be soaked in some PB Blaster to get it loose enough to push down. We used a 10mm deep socket on the air valve and two thumbs to push it down. Once it's down, it's a lot easier to pry the c-clip DOWN with a small flat head screwdriver rather than up, then when it's out of the groove, use another small flat head to pop it out of the tube.

Reassembly only took two hands though, but I'm sure it's easier with 3.5.