SuzukiSavage.com - front end disassembly

Commando_Al Ex Member	front end disassembly 12/05/05 at 11:08:30 I was breaking up the last of my parts bike last night, and couldn't get the forks out of the triple clamps. With other bikes (not savages) I just loosened the caps, smacked 'm with a hammer, and the forks dropped right out. No such luck here. Any ideas? There's lots of corrosion involved.
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bentwheel Serious Thumper 2005 No Login Offline Ride free, citizen Posts: 658 Sarnia, Ontario, Canada Gender:	Re: front end disassembly Reply #1 - 12/05/05 at 11:25:07 Spray wd40 around the clamp then insert a large screwdriver or small prybar between the pinchbolt threads and slightly open up the triple clamp.
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Max_Morley Serious Thumper Offline LT650 Luxury Touring & sidecar rig Posts: 1490 Moses Lake. WA Gender:	Re: front end disassembly Reply #2 - 12/05/05 at 14:07:36 Whoa!! The top nut is flanged and holds the tubes from dropping out. You have to remove it (the top nut) to get the tubes to drop out.
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babbalou Serious Thumper Offline Posts: 814 Lewisville, Texas Gender:	Re: front end disassembly Reply #3 - 12/05/05 at 17:19:43 Also, you may already know this, the turn signal clamps have to be loosened. My forks were a little tight. Had to tug some before they slid out.
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Kropatchek

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Re: front end disassembly
Reply #4 - 12/06/05 at 04:48:43

Max_Morley wrote on 12/31/69 at 16:00:12:

Whoa!! The top nut is flanged and holds the tubes from dropping out. You have to remove it (the top nut) to get the tubes to drop out.

Loosen the big nut just a little and give it a blow with a non steel hammer. When you support the upper triple tree with a bigger ( heavier) hammer the rods come loose from the uppper tree. Then loosen the nut a bit more and repeat.
Also read the other suggestions made.

The turnsignal bracket have a key to position them correctly so after loosening up the pinchbolt lift them about 1/4" and then you can turn them.

Greetz
Kropatchek Grin

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Never ask your bike to scream before her throat is warm.
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slavy Serious Thumper Offline smart cars for stupid people Posts: 710 Phoenix, Arizona Gender:	Re: front end disassembly Reply #5 - 12/06/05 at 07:09:16 Leave the bottom pinch bolts tight ! You need them. Use a wrench and take off the fork caps. Loosem the t.signals and the pinch bolts. Slide the fork out. Be careful, not to spill the oil.
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Commando_Al

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Re: front end disassembly
Reply #6 - 12/06/05 at 09:41:50

To clarify...

with the front wheel off the ground, I took the lower clamp bolts out, loosened the turnsignal brackets, backed the caps out a few turns, put a block of wood on the cap and hit it with a hammer. This is usually enough. The I ditched the block of wood and hit it directly with a sledge hammer (The tubes are shot anyway) and no movement. I think they're frozen with corrosion.

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slavy Serious Thumper Offline smart cars for stupid people Posts: 710 Phoenix, Arizona Gender:	Re: front end disassembly Reply #7 - 12/06/05 at 11:59:05 May be You should have red the posts of the people that were trying to help
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torque

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Re: front end disassembly
Reply #8 - 12/06/05 at 13:25:54

Commando_Al wrote on 12/31/69 at 16:00:12:

To clarify...

with the front wheel off the ground, I took the lower clamp bolts out, loosened the turnsignal brackets, backed the caps out a few turns, put a block of wood on the cap and hit it with a hammer. This is usually enough. The I ditched the block of wood and hit it directly with a sledge hammer (The tubes are shot anyway) and no movement. I think they're frozen with corrosion.

i see whats wrong... remove the axle and take the wheel off,remove the forks seperately.

its hard as hell to remove it in one piece,but if u must...take the top fork nuts off and the nut that holds the triple tree top on,then with your deadblow hammer,hit the bottom of the top triple tree,up towards the sky,after a few good blows it should come off.that way the bottom triple tree,fork tubes,wheel,fender,all come of in one piece.

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