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Old 07-29-2018, 04:51 PM
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XSSIVEUS XSSIVEUS is offline
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Location: Fairfield, CA USA
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Replacing Left Upper Fork Cover - 1100LG

Guys,

The 80 Midnight Special I picked up has a bent left upper fork cover that holds the headlight (from being dropped by last owner-took out left signal too). I have a NOS one ready to replace it.

Are there any tricks or bits of advice on removing the upper fork tube clamp (5K7-23340-00-90) to slide off the old cover and slide on the new one? I was thinking of removing the handlebar and laying it on the tank. Then loosening the upper fork clamp to allow it to be slid up and off the tubes along with the instrument cluster. However, I can't tell from the exploded diagrams if there is anything that will prevent this from working. I will have the bike on a lift under the frame to unload the forks. I'll also take the front wheel off to lighten the load on the tubes.

Thanks
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78 XS1100E, original owner
80 XS1100LG, restoration project
97 FLH, original owner
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Old 07-29-2018, 05:14 PM
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DiverRay DiverRay is offline
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Leave the front wheel on! It helps keep the forks aligned.
IIRC when I did my MNS (swmbo backed into the bike) I unbolted the instrument cluster and laid it forward, undid the center bolt, then the three pinch bolts and pulled everything onto the tank, with padding!
You will need to remove the headlight and remove the turn signal, or what's left of it. Watch the spacers and rubber bits that go on the forks.
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2011 Kawasaki Concours, BLACK
R1200RT Totaled 11-15-2016
XS1100 E '78 (winter project)
'99 altima, rain vehicle with ft8900.
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Old 07-29-2018, 06:29 PM
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Good advice. Also a good opportunity to clean up all the not-easy-to-reach parts in that area while apart.

Did you put your bike on a lift or just leave it on the ground?

Thanks Ray!

Glen
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78 XS1100E, original owner
80 XS1100LG, restoration project
97 FLH, original owner
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Old 07-29-2018, 10:03 PM
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DiverRay DiverRay is offline
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I didn't have a lift then, so I think I left it on the ground. Been a few years so the memory isn't as clear as it was.
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Ray Matteis
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2011 Kawasaki Concours, BLACK
R1200RT Totaled 11-15-2016
XS1100 E '78 (winter project)
'99 altima, rain vehicle with ft8900.
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