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[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.