Front Forks removal

[mikebike750]

I have to get the forks rechromed after seeing their condition when fitting new brake pads and discs and tyres.
Can anyone out there advise as to how much body work has to be removed to undo the pinch bolts on the fork clamps?
the service manual only says the upper fairing panels but having done this I still cant see how to get at the bolts.
i really cant afford to take the whole bike to a dealer
thanks

 

[Pmccor]

I just worked on this last week. On the right side you may need to remove the battery to see the pinch bolt. To get at them, you need to turn the bars to the opposite direction and the bolts come into view. The left side has the top bolt and the second bolt below the adjusting screw. It is quite easy to do when you see it.

 

[mikebike750]

thanks. i have done the non battery side. i can see that the battery has to come out and what about the airfilter intake? it mentions a lug that has to be turned to drop the pipe? is it that simple? perhaps i need more faith in the workshop manual!
its going to be a long wait to get the forks back...

 

[steve l]

The right (battery) side fork leg removal requires the air intake to be moved up. Loosen the rear bolt and unclip the front rubber mount. I found a T45 x 200mm bit was needed to remove the lower pinch bolts due to the restricted space. See photos.

The pinch bolts are fitted with Blue Loctite and I had to heat the bolts with a pencil flame to remove them.

 

[mikebike750]

hi thanks for the advice. i am nearly there. i see there is some kind of key to turn on the air filter intake to turn that drops it out of the way? then the battery to come out. its my first scoot and i have been so used to motorbike servicing before without all the bodywork. i have to place some faith in the manual and take it step by step. once the forks are out i can get them rechromed and serviced. many thanks. still waiting for brake discs!