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Buell Motorcycle Forum » Old School Buell » S2 Thunderbolt » Archive through March 31, 2009 » Fork Removal « Previous Next »

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Easy_rider
Posted on Sunday, January 04, 2009 - 02:30 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

How much prying/beating should I be doing to remove the forks from the trees? Removing the pinch bolts alone isn't doing it. I've knocked them down some, but things aren't loosening up.
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F_skinner
Posted on Sunday, January 04, 2009 - 02:33 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Roger, it they should slip right out. Make sure you removed the pinch bolts from the lower and upper trees. Don't ask me why I say that. Try a twisting motion when trying to remove them. Frank
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Phelan
Posted on Sunday, January 04, 2009 - 02:40 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

The coating on the forks is what keeps them from sliding right out. I pryed the lower tree open more and stuck a thick piece of metal in there, one just big enough to hold it just slightly wider than normal, then pryed the top tree. It'll slide right out then, assuming you don't still have the axle in : p . Repeat for the other side.
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F_skinner
Posted on Sunday, January 04, 2009 - 02:50 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Good idea Ross, make sure you are very careful, you don't want to nick the fork tube. Oh, I was assuming you have the front wheel and axle off the bike.
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Ratbuell
Posted on Sunday, January 04, 2009 - 03:00 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Yeah, my BF flathead screwdriver (aka Excalibur) makes a good wedge for opening up the "mouth" of clamps like the fork trees. When I did that, mine came right out.
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Easy_rider
Posted on Sunday, January 04, 2009 - 03:29 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

The wheel is off. The upper tree is off now. I'll try wedging something in the lower. They didn't drop when I used the screwdriver to widen the gap. I didn't want to pry too far and put myself in the market for a new tree. I'm already in the market for a new carb....
For the most part things have come apart relatively well. I'm getting to the parts that are well rusted. Will the breakers come out as an assembly or does that get masked off when painting?
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Buellistic
Posted on Sunday, January 04, 2009 - 04:05 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

When you tighten front axle on reassembly, be sure to "TORQUE"(my 1997 S3T 48-53 ft. lbs.) front axle nut so you do not over squeeze front axle spacer(same applies to rear axle nut(35MM 66-73 ft. lbs.)and is very important on BLAST's !!! ...

IF NUTS AND BOLTS WILL STAY TIGHT ON MIN. TORQUE, there is no reason to tighten more ???
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F_skinner
Posted on Monday, January 05, 2009 - 09:12 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Roger, how did it go? Did you slide those sucks out? Frank
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Easy_rider
Posted on Tuesday, January 06, 2009 - 10:50 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I got them out - I held the gap open while my stepson knocked them out with a plastic hammer. I thought about posting pics of the current state of parts but was too lazy to move the car. Need to do a little more disassembly, anyway. Two isolator allen bolts are rusted into the frame. I snapped one of my allen sockets trying to get it out. I'll attack with easy-outs this weekend.
The wiring harness is still attached as well. I'm not sure if I need to remove each individual wire from the breakers or if I can get it out as an assembly. Any thoughts? Also, if anyone has pics of the locations where the harness is zip-tied that will be helpful when the time comes for reassembly. The previous owner already had them removed. I should be able to figure out where most were by frame discoloration but from previous experience it only takes missing one to cause problems!
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Easy_rider
Posted on Sunday, January 11, 2009 - 09:10 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Didn't get much progress today. Spent some time on the rusted bolts. Got a set of the newer EZ-outs from Sears and decided that one was too small and the next size too big. Pulled out my old set and started drilling the pilot hole. 'Parently the bolts are hardened - or my bits are in bad shape. I haven't got a hole deep enough for the EZ-Out to get a good bite yet. At some point while looking at the holes on the other side I noticed that they are through the frame. About an hour later I decided that the Liquid Wrench that didn't seem to find it's way down from the bolt head just might work if I sprayed it in from the other side. I also spent an considerable amount of time wandering about the garage looking for my torch to try to help loosen things up without success. Lots of work to do, so I decided to let the Liquid Wrench soak a few days. Hopefully I'll have a frame free this week and I'll post some pics then.
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Firemanjim
Posted on Sunday, January 11, 2009 - 11:20 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Easy ,which bolts are rusted?
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Easy_rider
Posted on Monday, January 12, 2009 - 12:42 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Right side isolator plate, top bolts. I'm slowly working the rear bolt first. The wet look is from the spray early this afternoon. Gave it another shot from the back/inside while I went out to shoot this pic. It may just fall out by next weekend if I spray it a couple times a day!
Most of the disassembly by the manual was done to this point. It may well be that the previous owner to this point and decided to bail. Two other bikes and no distractions evident at home - I might of done the same!


mess
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