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[Jim]

Wanting to do Traxxion front suspension upgrade on my 08 CUSE, I have the service manuals and think I can probably do the R and R myself. Any experience or advice or tips would be greatly appreciated. I already have front fairing cover off for Hog Wire upgrade.

Jim

[Chief]

Wanting to do Traxxion front suspension upgrade on my 08 CUSE, I have the service manuals and think I can probably do the R and R myself. Any experience or advice or tips would be greatly appreciated. I already have front fairing cover off for Hog Wire upgrade.

Jim

The mechanical part is easy. Just besure to protect the paint.

Go for it.

[Boatman]

The mechanical part is easy. Just besure to protect the paint.

Go for it.

Like Chief stated, you are half way there if you have a service manual, proper tools, and torque wrench.  Follow the instructions in the manual.  You will also have to remove the lower inner fairing and the chrome panel below the headlight that is attached by the driving light bracket bolts.   Once the pinch bolts were loosened in the triple tree, one fork slid easily out and the other fork required a little more effort where it was stuck in the triple tree.  The front fender bolts also have lock tabs that have to be bent over for r&r..  Sometimes another hand is helpful too.  You can do it and the AK20's are worth the effort. 

The hardest part is the "wait" on getting your forks back from Traxxion and not being able to ride during that time.

[Boatman]

I also believe you need a 1 1/16" wrench (not socket) to remove the upper fork cap bolts so the forks will slide out.

[Jim]

Thanks for the tip's.

Jim

[Twolanerider]

Thanks for the tip's.

Jim

Now is when you replace the cowbells with something less plain if you have a mind to also.

[Jim]

Not to sound to stupid, what are cowbell's?

Jim

[Twolanerider]

Not to sound to stupid, what are cowbell's?

Jim

Oops, sorry.  The upper covers.  Those empty bells that are now sticking down. 

Stockers are at least chrome.  But there are other dressier options.  Now it's only an extra five minutes to change them too .

[Jim]

Any vendor's you would recommend?

Jim

[Twolanerider]

Any vendor's you would recommend?

Jim

Harley makes a few that are surprisingly inexpensive by Harley standards.  Ness makes some nice looking billet options also. 

[porthole]

It never ends ...........................

[Boatman]

It never ends ...........................

While the outer fairing is off:

Install bi xenon headlight kit.

Install in dash oil temperature gauge.

Wire your driving lights so they will work with the hi beams.

Install urethane handlebar bushings.


Come on fellas, help spend some more of Jim's money.   

[Jim]

While the outer fairing is off:

Install bi xenon headlight kit. Who's

Install in dash oil temperature gauge.  DONE

Wire your driving lights so they will work with the hi beams.  Great Idea

Thanks Boatman, all suggestions welcomed. my biggest problem in life has always been more money than common sense.

Jim

[Boatman]

all suggestions welcomed. my biggest problem in life has always been more money than common sense.

Jim

That applies to all of us here.  I assume you got your HWired from Hd-dude.  He also sells a bi-xenon headlight kit that is a lot better than the MOCO's and is a lot less money.  Talk to Jim (Hd-dude).  Do a search any many of us have his bi xenon kit (s) and are very happy.  Bob

[Twolanerider]

While the outer fairing is off:

Install bi xenon headlight kit. Who's

Install in dash oil temperature gauge.  DONE

Wire your driving lights so they will work with the hi beams.  Great Idea

Thanks Boatman, all suggestions welcomed. my biggest problem in life has always been more money than common sense.

Jim

Headlight upgrade is a night riding saving idea.  Original light pattern is simply bad. Almost dangerously so.

There is a HID kit with a small digital ballast that many of us have used here.  Easy to use and works well.  Contact a site member called HD-Dude.  He's a dealer for the vendor's product line and will sell them a bit cheaper than buying from the vendor directly.



Let's see, while the fairing is off there is also....   nah, you've got enough to look forward to 

[Jim]

Been looking at wiring diagrams for an hour now trying to figure out how to rewire spot's to stay on with high beam, it appears that the slice needs to be made at the connector [105 A/B] fairing harness. Th cruise / spot switch wiring has to be modified somehow? Any input? thanks in advance.

Jim

[Twolanerider]

Not my schematic.  Believe Jim provided this to the group.  It's an easy solution though.

Another option would be to find the connector currently unused in the harness that would go to the front fender tip light.  Use it to power the spots.  That's on all the time also.

[Twolanerider]

One thing to keep in mind if altering the spots.  Some states have as part of their state safety inspection that auxiliary lighting must go off when high beams come on. 

Your state might not.  Your tester might not be paying enough attention to catch it.  Just be aware of the possibility.

[porthole]

Let's see, while the fairing is off there is also....   nah, you've got enough to look forward to 

Instigator

[Jim]

Received my front forks back from Traxxion and having a hard time getting up into the upper tree? I have tried tapping botton of fork with a block of wood and a hammer with no effect. what am I missing? Lubricated with some window cleaner. Any help would be appreciated.

Jim

[sadunbar]

You are thru the pinch clamp and trying to get into the tree?  You removed the top nut from the fork, correct?  Can you post a picture?

[Jim]

Top nut removed, through pinch clamp and only about 1/4 inch into upper tree. Can't post picture right now but will lateer this afternoon. Thanks.

Jim

[Jim]

Here's the picture

Jim

[sadunbar]

Top nut removed, through pinch clamp and only about 1/4 inch into upper tree. Can't post picture right now but will lateer this afternoon. Thanks.

Jim

Did you re install the rubber stop onto the upper fork tube between the pinch clamp and upper tree?  If so, are you sure you are not hung up on the rubber stop?  If the rubber stop is up at the upper tree, slide it down the upper fork.  The rubber stop can easily get cocked a bit, which would bind things up and make it difficult to slide the fork all the way into the tree.

[sadunbar]

Did you re install the rubber stop onto the upper fork tube between the pinch clamp and upper tree?  If so, are you sure you are not hung up on the rubber stop?  If the rubber stop is up at the upper tree, slide it down the upper fork.  The rubber stop can easily get cocked a bit, which would bind things up and make it difficult to slide the fork all the way into the tree.

Now that I have seen your picture, be certain you are not getting caught/bound on the rubber stop.

[sadunbar]

Now that I have seen your picture, be certain you are not getting caught/bound on the rubber stop.

If you are sure you are sliding freely thru the pinch clamp, the only things I can think of that would stop you from fully inserting the fork, would be hanging up on the rubber stop, or having some build up that needs to be cleaned from the tree bore or burrs (rough edges) in the the tree bore...

good luck...

[Jim]

I have tried installing with out rubber stop also, with no luck. i wonder if the top cap on the forks are the same ones I sent to Traxxion and just modiffied or if they are different caps?

[sadunbar]

I have tried installing with out rubber stop also, with no luck. i wonder if the top cap on the forks are the same ones I sent to Traxxion and just modiffied or if they are different caps?

There is the fork tube plug (that retains the spring - should be installed from Traxxion in the upper end of the upper fork tube - if it wasn't there, the spring and guts of your fork would not be retained), then there is a rubber quad ring, then the fork cap bolt.  The fork should slide into the upper tree from the bottom side, then the rubber quad ring and fork cap bolt from the top side.  The only part of the assembly that engages the tree is the o.d. of the fork tube plug (the piece with the flats on it that is screwed into the upper end of the upper fork tube.)  If you are not hanging up in the pinch clamp or rubber stop, I can't think of anything to prevent the fork tube plug from fully engaging the tree...  Once engaged, then from the top is the quad ring and fork cap bolt.

[Jim]

The fork tube plugs are chromed and seam to be to large to enter upper tree, I dont remember if this is the way they were before I sent to Traxxion or not? Only thing I can think of is to grind or sand some of the chrome away from the fork tube plugs.

[sadunbar]

If the plugs (with the flats on them) don't fit into your upper tree, then you are right - the hole in the tree needs to get a bit bigger or the outside diameter of the plug needs to get a bit smaller...

[Jim]

Here's a picture of chromed fork tube cap, I think this should be a polished item to fit? anyone know? I wish I could call Traxxiom today, would like to wrap up.

Jim

[sadunbar]

Here's a picture of chromed fork tube cap, I think this should be a polished item to fit? anyone know? I wish I could call Traxxiom today, would like to wrap up.

Jim

Jim,

  I did almost exactly what you are doing.  I bought complete new front forks from Traxxion.  All new parts - new uppers, new lowers - new everything.  I then removed my original forks completely intact - and then installed the new Traxxion forks.  I did not have to "fit" or "polish" the fork tube plug to install it into the tree.  And it was chromed.  But, it would not surprise me to learn the chrome may be a bit thicker on yours - causing an interference fit.  I assume you do not have micrometers and snap gages to measure sizes, right?  If it were mine, and I was sure there was an interference fit, I would not hesitate to polish the o.d. of the plug down a bit to size it to the tree bore i.d.

Scott

[Chief]

Here's a picture of chromed fork tube cap, I think this should be a polished item to fit? anyone know? I wish I could call Traxxiom today, would like to wrap up.

Jim

The caps from Traxxion are not your original caps. Mine look to have been turned in a lathe to reduce the diameter just a bit. I'm guessing yours are oversized just a bit and are causing the problem.

[Jim]

Thanks for the input, the caps were chromed and should have been milled or pollished. 150 grit sandpaper with some elbow grease got the chrome off and the tubes slid in. I will have to call Traxxiom tommorow and suggest they add this to there final inspection. On to the handlebars.

Jim

[sadunbar]

Thanks for the input, the caps were chromed and should have been milled or pollished. 150 grit sandpaper with some elbow grease got the chrome off and the tubes slid in. I will have to call Traxxiom tommorow and suggest they add this to there final inspection. On to the handlebars.

Jim

Sounds like the o.d. was left oversize prior to chroming...  Traxxion will want the feedback that they caused you to work harder then necessary today.  Congratulations on getting it figured out and corrected...  good job...   

[Midnight Rider]

Thanks for the input, the caps were chromed and should have been milled or pollished. 150 grit sandpaper with some elbow grease got the chrome off and the tubes slid in. I will have to call Traxxiom tommorow and suggest they add this to there final inspection. On to the handlebars.

Jim

Jim...please let either Mike, Dan, or Max know about this...could be a fluke.  These are straight up guys and they will want to know about your fitment problem.  They make everything in house, so it could have been an error in the milling process for the end caps on our bikes...whatever the case, they will want to know so they can make sure it's an isolated incident and not a "batch" issue.  Sorry you had the problem, but glad you got it taken care of.

[porthole]

I also believe you need a 1 1/16" wrench (not socket) to remove the upper fork cap bolts so the forks will slide out.

1 3/8" inch. There really isn't a lot of room for a wrench.

I used a socket and drift pin, worked great.

[porthole]

Received my front forks back from Traxxion and having a hard time getting up into the upper tree? I have tried tapping botton of fork with a block of wood and a hammer with no effect. what am I missing? Lubricated with some window cleaner. Any help would be appreciated.

Same problem with mine. Turns out the "flats" were buggered up just ever so slightly. Filed them down and it slid in ok.

[porthole]

I have tried installing with out rubber stop also, with no luck. i wonder if the top cap on the forks are the same ones I sent to Traxxion and just modiffied or if they are different caps?

My fork upgrade came with new caps, old ones in a bag of spare parts.

[porthole]

Here's a picture of chromed fork tube cap, I think this should be a polished item to fit? anyone know? I wish I could call Traxxiom today, would like to wrap up.

Mine appear to be stainless, no chrome. Received them on 04-14-08

[Chief]

Mine appear to be stainless, no chrome. Received them on 04-14-08

When are you going to have it all back together?

[porthole]

When are you going to have it all back together?

I started last night. Had the problem with the cap not fitting and figured before it got too frustrating I'd finish later.
So instead I pulled the gas tank off, added the longer throttle cables that I got from Jim yesterday afternoon, then went and installed the Hot Demons heated grips.

Next - I have some re-wiring to do for the tourpak, and I have some extra terminals to put in the fuse box to move some wires around.

Then I figured as long as the front end is apart I would replace the right side cowbell that has a nice rock divot, no luck, no one has it in stock.

Having 2nd thoughts about the 330 Bitubo's, they look to be about 1.5" longer then what I have, if that is the case after I have everything back together I don't think I will be happy with them.

I'm doing my 24hours lock up right now so hopefully I'll be able to have it finished tomorrow (Wednesday) before I have to go babysit my pseudo granddaughter.