78 GS1000 Fork Caps

[wllara]

Ok hope this isnt too dumb of a question but how do I get the fork caps off, they have the air valve on top, do the unscrew or do you pry them out, Im kind of lost. I was going to take them to somebody to show me how but if I can do them myself, Im gonna go for it. I have a manual but it just says to remove fork caps. And can I get out the allen bolt at the bottow with just an allen wrench and a clamp to hold the fork?? Thanks

[SVSooke]

They unscrew.Do the allen bolt on the bottom first.May be a bit hard to get off but most times I just used a wrench with no problem.

[mike_of_bbg]

Judging from the parts fiche yours look like screw-in caps. See the "install progressive fork springs" guide on BassCliff's site.

http://members.dslextreme.com/users/storagecliff1/images/Install_Progressive_Fork_Springs.pdf

Unless you have an impact gun, usually you need to stick something in the forks to hold the lower cylinder. There are many options if you search the forums. 7/8" spark plug socket, backwards, on several extensions. Wooden broom handle might work. Threaded rod with locked nuts.

[wllara]

Fork Cap

So I tried undoing the allen bolt, but it just spun so Im gonna take it to a guy to show me the whole process, he told me he would use an impact wrench, I dont have one.

[chuck hahn]

Hold the uppers in a vice wrapped in rubber or whatever to prevent them from being damaged. Heat the bolt with a torch. This will soften any locktite on the threads. Also you may want to make a tool to hold the inner rod so the bolt can be removed..heres pics of my home made tool the bolt on mine is a 19 mm and it fits the 1000s. But you get the idea here..

[Octain]

What Chuck is trying to say is there is a nut on the other end of that allen bolt. But it's way inside the inner fork tube.
What many do is losen the allen bolt first thing. Even before they remove the forks from the bike. Bust it lose then take the rest of it apart.

The caps unscrew. I use a cresent wrench.

[chuck hahn]

There isnt a nut..its a recessed like a 12 point socket that the head of the bolt fits into and holds it so you can loosen the bolt. If you have the tool any hand held allen wrench will usually loosen the bolt without much effort. Once you get one apart yopull see what we are trying to discribe.

[Octain]

Chuck is right, it's not a nut but it's what comes to mind.
Once ya get the allen bolt lose and ya remove the fork tube from the mount(tree), remove the cap and all the innerds from the tube you can use a flashlight to see the "nut".
I used a plastic broom handle on the "nut" with no problems and I didnt losen the allen bolt prior to removing the fork(tube).