[camaro 22]

I'm rebuilding my 03 R1 I bought wrecked, and the fork are bent on it. I have a whole new front end, forks, trees, stem ect. What's the steps on removing the forks and replacing them? I have a bike jack also. I losened the big stem nut on the top tree, and the clip on screws. How do I get it off now? Any help would be appreciated.

Shawn

 

[martinc]

Got to jack it up first (use a rear stand too);

Next,remove the top triple clamp.
Then remove the ramped collars (2 nuts and a rubber washer)..it will drop.

Dont forget to remove all switch pods,lever perches and throttle assembly before removing the fork

 

[firehawk2003]

May be obious....but it would be advisable to remove the front wheel, axle, calipers and front fender first. Best tool for removing the axle is a 5/8 spark plug socket (put a socket extension into the deep end, and snap it into the reciever. Use the outside hex on the socket; fits right inside the axle!)

Also, a mistake I commonly see, is guys using a screwdriver to pry open the upper/lower clamps after the pinch bolts are loosened. If you back the pinch bolts off far enough, there's no need for this; the forks will slide right out. Also, you won't scratch your fork tubes and clamps!

There are also special procedures for putting the works back together.....

Need to know?

 

[R1Budha]

May be obious....but it would be advisable to remove the front wheel, axle, calipers and front fender first. Best tool for removing the axle is a 5/8 spark plug socket (put a socket extension into the deep end, and snap it into the reciever. Use the outside hex on the socket; fits right inside the axle!)

You don't need to do that on an 03.
Just remove the bolt from the one side and push the axle out after loosening the axle pinch bolts.
Why spin the axle, when the retaining bolt come right out?

 

[firehawk2003]

You don't need to do that on an 03.
Just remove the bolt from the one side and push the axle out after loosening the axle pinch bolts.
Why spin the axle, when the retaining bolt come right out?

You're right, Budha. Didn't realize the axle wasn't threaded like the 98-01. Bad gouge on my part. :2bitchsla

Well, I know the gouge is still good for people with 98-01's, for whatever it's worth. Anything else Yamaha changed and didn't notify me about? Guess I need to catch up with the times! Next thing you know, there's going to be undertail exhausts!

 

[R1Budha]

You're right, Budha. Didn't realize the axle wasn't threaded like the 98-01. Bad gouge on my part. :2bitchsla

Well, I know the gouge is still good for people with 98-01's, for whatever it's worth. Anything else Yamaha changed and didn't notify me about? Guess I need to catch up with the times! Next thing you know, there's going to be undertail exhausts!

and wierd looking inverted swingarms..............:lol

 

[martinc]

and wierd looking inverted swingarms..............:lol

...or even freakin holes in the top fairings...

:crash

 

[camaro 22]

Thanks for the replies guys. I was able to figure it out last night after posting this thread. The part I was most unsure about was pulling up on the upper tree. Was nervous about bending it or messing it up, but got it up ok. Now I just have to take off the damaged radiator and put the new one on, and put the new headers on also, then have to reinstall the good forks and trees and wheel back on.

 

[firehawk2003]

Kinda wondering why you needed to take the forks off to change the radiator and headers......I've removed them several times without taking the forks off.

Abe, read his first post. His forks were messed up, too. He's replacing the whole works.