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[480Ruger]

I’m trying to install Progressive Suspension’s Monotubes and I cannot remove one of the front forks.  I tried everything I could think of.  Even jammed a wonder bar between the triple trees and used the clamping bolt removed from the back and screwed in from the front as a spanner against the wonder bar.  Frammed on the loosened cap bolt with a dead blow hammer.  Still wouldn’t budge.  I left it last night with a coat of Kroil Oil.  ANY IDEAS?

[mattm]

I had the same problem when I did mine.  Same side even.  It turned out to be a bit of corriosion between the top triple clamp and the top of the fork (just below the top cap).
I sprayed some penetrating oil on both upper and lower triple clamps, waited a bit and they used a 1/2 extension and a db hammer to wack the top of the fork.  Be careful of the inner fairing and other expensive bits close by.  It doesn't matter if you booger-up the fork cap, because this part is not used with the monotubes.  Remove the top fork cap bolt, and you will find that the female end of the 1/2 extension fits in the hole pretty well.  When I put everything back together, I used just a hint of antiseize at these spots, just in case.

[480Ruger]

Glad to hear.  I will try it as soon as I get off work.

[480Ruger]

Three hits with the 1/2" extension after a night of Kroil oil and it popped right out.  Thanks for the 1/2" extension tip.  I was about to cut up a broom handle.  It was all rusted up at the top around the fork tube plug.  Just six months old and already that bad.

[Indenial]

Be sure to install both the preload spacers in your Monotubes.

[mattm]

Glad it broke free for you.  Like I said, I used a little antiseize when I put the forks back in.  The monotubes rock, you will like them.

[480Ruger]

I’ve read all the problems you had Indenial.  Sorry the monotubes didn’t work for you.  I used all 4 - ¼”spacers on each side.

I missed the section in the service manual about having to replace the 6mm allen bolt and copper washer in the bottom of the forks or I would be riding today!  I’m just glad to do the front and back myself so I know a little more about the bike each time.

[Boatman]

Happy you got it out.

Either they are stuck or they slide out unexpectantly when loosening the pinch bolt-go figure.

Regarding the 6mm allen w/washer-Traxxion never changes them nor puts sealer on them as the sealer can clog their inner workings-FWIW..

I am aware of what the service manual states-on regular innards I just put #2 non hardening Permatex on the threads.   #2 Permatex is probably the most overlooked but best sealer there is.  My dealer doesn't even stock them-sad.

[Indenial]

Let us know how you like them. Hope they work well for you.