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Author Topic: Front fork replacement  (Read 4960 times)
BobbyW
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« on: July 24, 2021, 17:36:39 »

I have the replacement forks for my 250sl but before I start pulling the bike apart, can anyone in the tech dept advise on the procedure for removal of the old forks?
Obviously wheel out, mudguard off and brakes removed, but as she sits I can see the fork clamps in plain sight.
Is it just a case of undoing the nuts, prising the clamps open and dropping the old forks, replacement the reverse, or are there some hidden problems I need to know first.
Thanks in advance.

Second problem is the top box.
The lock has come apart, the nut sheared and the spring sprung off. I've drilled and tapped but it won't stay locked shut.
I have the barrel out but cannot remove the lock assembly from the lid.
Any suggestions other than the rubber band I'm using at the moment.
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Never ride faster than your guardian angel can fly
02 X9 250SL 1988 BMW K100rs until old age took me off the road.
spannerman
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« Reply #1 on: July 25, 2021, 09:16:22 »

To remove each fork stanchion, you may have to fully remove each of the pinch bolts from the yoke for them to slide out.
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Dave Weller, Chatham VespaGTS250, Royal Enfield 350 HNTR. NC750X
Dave Milnes
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Millom Cumbria


« Reply #2 on: July 25, 2021, 13:48:24 »

Somewhere way back someone once said the top box used the catch and lock from a Fiat Panda tailgate but they are rare as well now as I assume they meant the original Panda.
If having loosened the clamps and wedging them open a little if they won't pull out downwards, push them up instaead and check for a thin wire circlip in a groove at the top.
Some forks have a cap with a hex socket or nut that is just a bit too large to drop through the clamps so you have to remove this before slackening the clamp bolts. It may be under slight spring pre-load so be carefull. When you fit the new forks the cap or circlip sits into a recess in the yoke clamp so aligning both forks.
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2021 Honda NSS750 Forza
Anderton 2004, Pen-y-cae 2005, Matlock 2006, Hay on Wye 2007, Minehead 2008, St Florence 2010, Newent 2011, North Kyme 2012, Betsw-y-coed 2013, Hardraw 2014, Parkend 2015, Whitby 2016, Mundesley 2017, Derby 2018, Telford 2019, Lake District 2024, Durham 2025
BobbyW
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« Reply #3 on: July 25, 2021, 21:05:03 »

Thanks for the advice, the replacement forks have the hex cap.
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Never ride faster than your guardian angel can fly
02 X9 250SL 1988 BMW K100rs until old age took me off the road.
Dave Milnes
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Millom Cumbria


« Reply #4 on: July 26, 2021, 09:18:44 »

The screw cap types are good because it's easy to change the oil or the springs or if required. Don't tip them or you will spill the oil so a bit more tricky to remove and refit.
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2021 Honda NSS750 Forza
Anderton 2004, Pen-y-cae 2005, Matlock 2006, Hay on Wye 2007, Minehead 2008, St Florence 2010, Newent 2011, North Kyme 2012, Betsw-y-coed 2013, Hardraw 2014, Parkend 2015, Whitby 2016, Mundesley 2017, Derby 2018, Telford 2019, Lake District 2024, Durham 2025
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