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How to Remove Your Front End

Discussion in 'How-To' started by alhall88, Jul 10, 2007.

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  1. alhall88

    alhall88 UAW

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    This topic is for the complete removal of your front end, it does not cover however seal and fluid changes.(sorry) So if your thinking of changing your front end out then this is for you. I will assume that you already know to disconnect your battery and also how to remove your tank.
    So here's a shot of that already complete
    [​IMG]
     
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  2. alhall88

    alhall88 UAW

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    Next unplug all your harness, disconnect the throttle and clutch cables,then loosen the 2 handlebar bolts from under the top triple tree.
    [​IMG]
     
  3. alhall88

    alhall88 UAW

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    Now remove the headlight by either from the bolt uder the bottom tree or the 2 on the sides of the mount.
    [​IMG]
     
  4. alhall88

    alhall88 UAW

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    Next I would remove the fork brace along with the front fender (sorry not shown). So we will remove the front wheel now, so go ahead and remove the bolt on the left side of the front end.
    [​IMG]
     
  5. alhall88

    alhall88 UAW

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    Now we can remove the front axle so first we have to loosen the 2 pinch bolts on the right side of the front end on the lower leg.
    [​IMG]
     
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  6. alhall88

    alhall88 UAW

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    Now while holding the wheel start turning the axle with an allen wrench, its not threaded but this helps to remove it.
    [​IMG]
     
  7. alhall88

    alhall88 UAW

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    Ok we will now remove both the fork legs at this time so make sure you have a 1-3/8 socket handy. First we loosen and remove both the bolts on the top tree.
    [​IMG]
     
  8. alhall88

    alhall88 UAW

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    Now the only thing holding the fork tubes in are the 2 pinch bolts on either side so when you start to loosen these make sure you are firmly holding the tube as it slides down. Also be warned that they are still full of fluid so don't tip them to much.
    [​IMG]
     
  9. alhall88

    alhall88 UAW

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    The only thing left at this time is the triple tree assembly.Not shown but important is that there is a set screw on the backside of the lower tree that prevents the main bolt from loosening up. So you must first remove that then loosen the bottom bolt under the lower tree.
    [​IMG]
     
  10. alhall88

    alhall88 UAW

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    Once this is removed you can then lower the bottom tree with the bearing and follow with the upper tree and main shaft bolt, and the upper bearing.
    [​IMG]
    [​IMG]
     
  11. alhall88

    alhall88 UAW

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  12. alhall88

    alhall88 UAW

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    Providing what your next front end will be you will want to probally save your original top dust shield and the fork stop thats held on with 4 screws on the bottom tree.
    [​IMG]
     
  13. alhall88

    alhall88 UAW

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    Here's a shot of the forkless frame and also heres an important note. Make sure before removing your front end record some measurements from say the bottom of the inside edge of the neck. This measurement is when your frame is nice and level from the factory so the ideal state would be to be able to reproduce this height with whatever front end you choose.
    [​IMG]
     
  14. alhall88

    alhall88 UAW

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    And finally here's what you will be selling on ebay to re-coup some of your cost of a new front end. I sold my old front end with the turn signals and front brake caliper for $575.00.
    [​IMG]
     
  15. Tim

    Tim a.k.a. BubbleHead
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    Great write-up, thanks for sharing.
     
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