Another Newbie restore project

Jetblackchemist · Post by **Jetblackchemist** » Fri Feb 10, 2012 9:03 pm

I'm only 5'-11, but the seat position places my feet straight down on the foot pegs when riding instead of back or forward, which I find is more comfortable. The shiny thing on my side cover is a electric cigarette lighter mod, which is good for smokes as well as plugging in 12v accessories . It was one of the main reasons I researched and made the mod to 12v besides not wanting to be a battery nanny.

Spokes · Post by **Spokes** » Sat Feb 11, 2012 3:57 am

Question for the experienced, how do you remove the chrome caps on the forks, I'd like to remove my front fender? There seems to be a slot on the bottom to pry it out but I'm not having any luck and don't want to damage to the forks body, I already bent my screw drive tip; any advice would be helpful.

Those "caps" are actually a bolt button head. This bolt holds your front suspension and fender. See below.

Nobogy · Post by **Nobogy** » Sat Feb 11, 2012 5:59 am

Jetblackchemist wrote:I'm only 5'-11, but the seat position places my feet straight down on the foot pegs when riding instead of back or forward, which I find is more comfortable.

I know what your talking about, you either need to sit forward and hug the bars or further back. 12v accessories, I like

Thanks Spokes the picture says it all, I thought I would try and remove as much as I can without too much weight bearing force, looks like the wheel will need to be removed and the frame supported, so that will have to wait. This forum rocks!

Jetblackchemist · Post by **Jetblackchemist** » Sat Feb 11, 2012 9:56 am

Hey spokes, the front wheel has to come off first then the fender nut inside, the cap is T-ed at the bottom and comes off last, you have to lift and give it a twist to free the inner T shape. The image isn't clear off how it actually works the bolt is one of those that locks itself when you loosen the nut then, pushing the bolt from the inside the cap pops down and the bolt slides out then, the lift and twist to unhook the cap hinge.

Spokes · Post by **Spokes** » Sat Feb 11, 2012 4:45 pm

You lost me on the removal procedure Jet.

I've removed and installed wheels and suspension on 1/2 dozen Ca95 & Ca160's which both share the same front end set ups.

After securing the bike so the front wheel is suspended and stable,

1.) Remove the speedometer cable from the hub.
2.) Remove the torsion link from the brake hub to the fork frame.
3.) Remove the front brake cable.
4.) loosen the axle clamp bolts
5.) Remove the axle nut
6.) hold the wheel firm and pull or drive the front axle out and remove the wheel, brake hub and speedometer drive together.

The fender is held on by the upper shock support and the inside rear pinion support. You may have to remove the lower fork chrome trim at this point to to put a wrench on rear pinion head to loosen the nut that secures the fender support/suspension pinion.

To drop the front suspension (after the fender is removed)remove the two(2) lower suspension pinions and drive out the upper shock support and the whole assembly will become free to remove.

Usually if there is no suspension issues then there is no reason to remove the front suspension assembly.

Jetblackchemist · Post by **Jetblackchemist** » Sat Feb 11, 2012 5:05 pm

my apologies the jump to page 2 muddled who was asking what exactly, My upper fender bolt that hold both the fender and the upper shock isn't chrome on the end, it had to be tapped out from the back popping the chrome part out. My chrome part hinges out of the way of the bolt. The chrome disk had a "T" shape hinge attached that had to be turned 90 degrees to free it from the front fork. Again my apologies for the confusion. Number 18 in the schematic isn't one piece on my bike, but consists of the bolt then the chrome cap t-hinge.

grandolepete · Post by **grandolepete** » Mon Feb 20, 2012 5:43 pm

love the clubs just ordered myself a set with bar end mirrors. been looking for a pic so i could get an idea. odd though, i took my og bars off and inverted them, ala clubs, really soft line.....