Replacing front fork boots
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  1. #1
    Senior Member TW_in_BC's Avatar
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    I just noticed mine are cracking and starting to gape...is replacing them a difficult procedure, do I have to dismantle the tree or remove the forks?
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  2. #2
    Senior Member Rainman's Avatar
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    Very easy to do. You do have to remove the forks. I did mine and was intimidated before I started, but once I dug into it, it turned out to be very doable.



    Remove front wheel.

    Remove fender

    Remove screw that holds brake cable to fork.

    Remove pinch screw and slide the fork down. You'll need to have the bike up in the air.
    If you can't find it, grind it

    1990 TW200

  3. #3
    Senior Member TW_in_BC's Avatar
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    What about re-alignment? Apparently it is quite important...How do I do this properly?
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  5. #4
    Senior Member Rainman's Avatar
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    The bottoms of the forks below the fork boots swivel, so the axle will line those up. The manual says to have 6 MM (confirmed, just looked at the manual) of fork protruding from the upper triple clamp. I used a bolt, a couple of washers and a nut to make a measuring tool. I laid washers on the bolt until I got it the same height as what was prodtruding from the upper triple tree and then I put on a nut to hold it all together.

    If you can't find it, grind it

    1990 TW200

  6. #5
    Senior Member TW_in_BC's Avatar
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    Clever!



    I didn't realize that the forks would swivel...guess it makes sense. Not such a daunting or intimidating task after all...
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  7. #6
    Senior Member admiral's Avatar
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    To add too what Rainman has mentioned, I have some photo's in my "A TW without Forks is Like a Duck without a Bill" thread that may be of some visual assistance. Though not a step-by-step process, I replaced a buddies fork boots and seals. Later today I will post some of the photo's from the actual fork seal work, though you only mention the boots.



    But as Rainman has mentioned, fairly easy to accomplish. I can see where someone would be a little worried about taking the forks off and putting them back on correctly. Once you get started, replacing the boots should only take an hour or two (depending on the number of interruptions) giggle.



    Good luck with your "new boots".





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