Fork assembly

[Rickrod3]

Hi All:

Assembling front forks and there is about a 1/4" gap between the head light holders and the top of the handle crown.
I also noticed that the stem is not flush with the top of the handle crown. The steering crown goes all the way Does to the ring nuts.
I've tried reseting it a few times and it always ends up the same way.
Is that normal?

What is the sequence for tightening up all of the pinch bolts. and steering stem bolts.

Thanks in advance
Rick

[DGXSER]

Sounds like your saying the triple trees appear to be to far apart form each other.

Loosen the top triple tree pinch bolts on each side, then loosen the pinch bolt on the top triple tree. Now tighten the steering stem bolt that goes into the top of the steering stem to 61 ft-lbs, then tighten the pinch bolt to 14.5 ft-lbs. Next, retighten the upper pinch bolts that hold the forks.

[crazy steve]

Have you got all the parts in there? There's two chrome 'guides' for the headlight ears, as well as a rubber 'gasket'. If those are missing, the ears will be sloppy. These take up about a 1/4"....

As far as tightening the various bolts, this is the order I use. The front axle and fender should be off or loose.

1. Lower pinch bolts.
2. Steering stem.
3. Loosen lower pinch bolts.
4. Set fork height, tighten upper pinch bolts.
5. Lower pinch bolts.
6. Front axle.
7. Front fender.

'78E original owner

[Rickrod3]

Have you got all the parts in there? There's two chrome 'guides' for the headlight ears, as well as a rubber 'gasket'. If those are missing, the ears will be sloppy. These take up about a 1/4"....

As far as tightening the various bolts, this is the order I use. The front axle and fender should be off or loose.

1. Lower pinch bolts.
2. Steering stem.
3. Loosen lower pinch bolts.
4. Set fork height, tighten upper pinch bolts.
5. Lower pinch bolts.
6. Front axle.
7. Front fender.

'78E original owner

I have the 2 chrome washers I didn't remeber a gasket.
Do you have a parts fiche that shows them, or a picture so I know what to look for?
How do you set you fork height?
I was going by and old mark left on the fork tube into the lower triple tree.

Rick

[crazy steve]

I have the 2 chrome washers I didn't remeber a gasket.
Do you have a parts fiche that shows them, or a picture so I know what to look for?
How do you set you fork height?
I was going by and old mark left on the fork tube into the lower triple tree.

Rick

There's two chrome washers (called 'cover guides') on each side, both with a 'lip' on them; the top ones are slightly smaller in diameter, and the lip goes up, with the recess over the fork ears. On the lower ones, the lip faces down towards the lower tree, and this is where the 'gasket' goes, under the lip. The 'gasket' looks like a piece of black hose that's been cut; it's about 1/4" high and may be split so you don't have to remove the top tree to install. This rubber is what make the headlight ears tight. The parts fiche doesn't show these very well at all, but are parts 14, 15, and 16 when you go to to the 'forks' page. Here's the site...
http://www.benefiscal.co.uk/

They call the rubber a washer here.

As far as 'setting' fork height, that's just a matter of making sure both fork tubes protrude the same distance out of the top tree. The closer you can get this, the less chance of fork bind.

'78E original owner

[Larrym]

Going Fiche-ing without Bait

Steve is right:



14 2H7-23163-00-00 GASKET (42H-23163-00-00)
15 2H7-23116-00-00 GUIDE, COVER LOWER
16 2H7-23115-00-00 GUIDE, COVER UPPER

In the fiche they aren't shown installed on the covers, parts #33 and #34, but rather slipped onto the fork tube in the way they should be installed. Without that gasket/rubber piece the "ears"/covers would be DAS FLOPPIN.

Here's the direct link to the fiche view:

http://www.benefiscal.co.uk/imagine....e=FRONT%20FORK

Always takes a long time to connect/load/display for me.

HTH

[oseaghdha]

Maybe faster connection here

Always takes a long time to connect/load/display for me.

Try here:
clicky

[Rickrod3]

Ok thanks I'll seach my garage floor for the gaskets.

Rick

[Rickrod3]

Hey Guys:

couldn't find them but: some 1-1/2 " slipnut washers seem to fit perfectly. they are make of neoprene.

I looked at my XS650 and it has them installed right above the top chrome washer in between the top triple tree. They also seemed to be dried out. Since the bikes are the same year; the ones for my xs11 were probably dried out too

Rick

[Rickrod3]

Sorry cannot get all my thoughts together, Or I'm trying to be the one man thread

Remenber Rocky and Bullwinkile, How they always had the second title?

well nevermind.

The manual says to use a locktite lock and seal on the bottom bolt that screws into the damper.

Seems like it may make it an even bigger pita to remove in the future.
As far as a leak through the bolt, isn't there a copper washer?

Rick

[bikerphil]

If you're gonna use Locktite, use the blue, it'll come apart next time fairly easily. Stay away from the red. I usually don't use any at all, and never had a problem with one loosening up, YMMV. The copper washer keeps the oil from leaking, provided that area is clean prior to installation.

[Rickrod3]

If you're gonna use Locktite, use the blue, it'll come apart next time fairly easily. Stay away from the red. I usually don't use any at all, and never had a problem with one loosening up, YMMV. The copper washer keeps the oil from leaking, provided that area is clean prior to installation.

Thats kinda what I was thinking

Thanks Phil