cant get lower forks on


Information and questions on GL1100 Goldwings (1980-1983)
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C130Mech
Posts: 2
Joined: Sun Mar 10, 2013 9:02 pm
Location: azle, texas
Motorcycle: 1980 GL1100

cant get lower forks on

Postby C130Mech » Wed Apr 10, 2013 8:26 pm



-Hi everybody,

I'm new to Goldwings and am having a bit of an issue. I recently purchased an 80 1100 and have been doing some maintenance(Randakk carb kit, tires, fork seals). I've finished up replacing the fork seals and I cannot get the lowers on. I can tell that its started to slide past the bushings but that's as far as she'll go. I don't want to be too aggressive. I've removed the upper because I thought that might help but no luck. I've done plenty of seals before but the bushing thing is new to me. Any help would be greatly appreciated.



User avatar
virgilmobile
Posts: 7663
Joined: Sun Sep 19, 2010 5:39 pm
Location: Denham Springs,La.
Motorcycle: 1988 GL1500 I
Previously owned
78 GL1000
81 GL1100
82 GL1100 I
83 GL1100 I
83 GL1100 standard
84 GL 1200 I

Re: cant get lower forks on

Postby virgilmobile » Thu Apr 11, 2013 9:41 am

I would start from scratch.One piece at a time.
Before I completely service the front end,I remove the fork tubes,lay them together and roll each one looking for a bent fork.If one is bent,you'll see a gap show up quick.There is a "bent" tolerance listed in the manual.
I also put the forks back on and using a piece of glass,check that the forks are EXACTLY parallel.They can be tweaked.

Start assembly at the bottom of the fork.

Put on the lower slide bushing....When it's on the fork,it should be very snug.If it's loose,remove it and gently squeeze it till you get the gap closed.Back and forth overlapping.
Remove any burrs.
Then slide it into the tube.It should be snug but no binding.

Put on the upper slide bushing from the top...
Slide the fork into the lower and seat the upper bushing with a appropriate tool....I use a PVC coupler or PVC piece of pipe to tap it into place...It won't distort the bushing.
If it binds,you will have to determine why...

Your dealing with very small tolerances so any "dings" can bind it up.
The forks should move butter smooth full stroke when done.

Once the fork will slide in the tube,add on the rest of the parts to seal it up.

Final assembly on the bike is specific,step by step.It can't be just bolted back together...Every time I tried that,it ended up binding.

C130Mech
Posts: 2
Joined: Sun Mar 10, 2013 9:02 pm
Location: azle, texas
Motorcycle: 1980 GL1100

Re: cant get lower forks on

Postby C130Mech » Thu Apr 11, 2013 7:28 pm

I left all of the bushings in place so that explains it. I cant get the lower leg bushing out though and i dont want to destroy it.

User avatar
virgilmobile
Posts: 7663
Joined: Sun Sep 19, 2010 5:39 pm
Location: Denham Springs,La.
Motorcycle: 1988 GL1500 I
Previously owned
78 GL1000
81 GL1100
82 GL1100 I
83 GL1100 I
83 GL1100 standard
84 GL 1200 I

Re: cant get lower forks on

Postby virgilmobile » Fri Apr 12, 2013 9:25 am

Can't get the bushing out of the slide or off the end of the fork?




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