HELP! 1978E Fork disassembly

[Nubian]

Hello all!
The E has a different cap than my 11H. Can't take it apart not sure how FSM shows a different cap.The one i'm working on has a metal cap with a sunken screw on top. That screw is seized don't want to force it until i'm sure it has to be removed. The allen head bolt on bottom is spinning while the top is firmly held but yet does not loosen assembly.

[motoman]

First question: Do you have the forks off bike? If not, need to remove them first. Some one will chime in I'm sure as to the pictorial that shows/instructs. A rod or such with a socket attached is used to hold inner nut, then spin allen bolt on bottom loose using an allen socket and air gun. That's just from my getting shorter memory. If that happens to be the H your working on, originally cap on top has an angled special Schrader valve screwed in center of cap. As far as I remember, that valve is NOT a normal Schrader valve that has pipe threads.

[bikerphil]

The sunken screw is just preload adjustment, it has 3 positions so you want the counter clockwise most position for the least tension. Use the hex head to remove the cap, either a 1 1/16" or 27 MM socket. You will need to fabricate a tool such as the one shown below to hold the damper rod from spinning. Use the tool with a long 3/8" extension and a 19MM socket. The size of the hex head tool is 19MM.

[bikerphil]

One thing to add, break the caps loose while still on the bike, much better to hold the tube in the triple tree instead of a in a vise.

[TopCatGr58]

But I would suggest first loosening the TT bolts, and slide the tube UP in the TT assembly a couple of inches so that the TT clamps won't be squeezing the upper fork tube around the cap which can also squeeze the fork cap making it harder to remove.

T.C.

[bikerphil]

Yep, good call TC.

[skids]

Support the front of the bike prior to pulling the caps or the forks will collapse and the bike will nose-dive.

[RichW1064]

"nose dive"... lol... that was a lesson that I learned some years ago as the spring flew past my ear and over my shoulder... I was working on an older dirt bike and had to build myself one of those lift jacks that sit under the frame with a long handle to tilt down on... lifting the bike up and then I was ready to try and locate the fork cap... man, what a lesson that was... lol...

[Nubian]

Thank you all, had to step away but all turned out well.

[Nubian]

Started reassembly and noticed a washer missing from both forks that the manual shows should there. is this critically necessary? I think it should be a copper washer if memory serves me right. It's at the bottom of the fork, it's a allen head bolt that secures the inner compression cylinder.

[Nubian]

Uhmm..

Started reassembly and noticed a washer missing from both forks that the manual shows should there. is this critically necessary? I think it should be a copper washer if memory serves me right. It's at the bottom of the fork, it's a allen head bolt that secures the inner compression cylinder.

Disregard above! found info in another thread it is necessary and is made of copper, as much as I may try to impose on him, my buddy has no idea how fortunate he is to have this forum available.