Went to replace the fork seals on my daughters RT180 this afternoon. Thought it would be an hour job but it's eating me up.
I cannot get the fork caps off!!! After pulling the wheel I attempted to get the caps off with the legs still in the tree for support. It's a 91 model with a 19mm allen head in the cap. Yes it's that big! Not having a 19mm allen I used a 3/8" bolt turned upside down with a couple nuts threaded on to "get on' the caps. Perfect homemade tool with a perfect fit.
I torqued up on those suckers for all I was worth. Loosened the upper pinch bolts on the tree thinking maybe they were "pinching" the caps tight. Not likely but what the heck. Tried with a cheater bar and still no luck. I stopped before I broke something. Iamb 6' and 215 lbs. so trust me lack of torque was NOT a factor.
Been riding and wrenching for 31 years and have done lots of seals but I'm stumped. Does anybody have a service manual or advice? Surely the cap is not a left hand thread!?!?
Granted it's been more than several years since I've done seals but my plan of action was:
1. Remove wheel and caliper.
2. Remove fork caps.
3. Remove forks from triple tree, remove spring and drain.
4. Remove damping rod bolt at bottom of forks.
5. Pull forks apart as a slide hammer to disassemble.
Problem is I can't get past Step 2!!! Driving me nuts. If someone has a service manual laying around or practical experience please advise.
I'm having such a hard time with the caps I'm now worried if the damping rod bolt is going to also give me trouble.
I should mention, the bike is like new, still on original OEM tires. The caps are not rusted on or gunked up due to exposure to the elements, etc.
Thanks in advance.
Rick
I cannot get the fork caps off!!! After pulling the wheel I attempted to get the caps off with the legs still in the tree for support. It's a 91 model with a 19mm allen head in the cap. Yes it's that big! Not having a 19mm allen I used a 3/8" bolt turned upside down with a couple nuts threaded on to "get on' the caps. Perfect homemade tool with a perfect fit.
I torqued up on those suckers for all I was worth. Loosened the upper pinch bolts on the tree thinking maybe they were "pinching" the caps tight. Not likely but what the heck. Tried with a cheater bar and still no luck. I stopped before I broke something. Iamb 6' and 215 lbs. so trust me lack of torque was NOT a factor.
Been riding and wrenching for 31 years and have done lots of seals but I'm stumped. Does anybody have a service manual or advice? Surely the cap is not a left hand thread!?!?
Granted it's been more than several years since I've done seals but my plan of action was:
1. Remove wheel and caliper.
2. Remove fork caps.
3. Remove forks from triple tree, remove spring and drain.
4. Remove damping rod bolt at bottom of forks.
5. Pull forks apart as a slide hammer to disassemble.
Problem is I can't get past Step 2!!! Driving me nuts. If someone has a service manual laying around or practical experience please advise.
I'm having such a hard time with the caps I'm now worried if the damping rod bolt is going to also give me trouble.
I should mention, the bike is like new, still on original OEM tires. The caps are not rusted on or gunked up due to exposure to the elements, etc.
Thanks in advance.
Rick