01 vulcan 1500 classic fork and spring removal

[NCDave]

ok guys....while this is fresh in my mind, here's a few tidbits of information about how I got my forks off and the springs removed.

Several of these steps can be done in slightly different order, but hopefully you'll get the idea and this will provide some pointers. If you have any questions, PM me and I'll try to help you!

1. Remove all aftermarket components like windshield and lowers. Not sure about light bar....I don't have one. You should be back to "stock" form on the front end of the bike.

2. Remove brake caliper.

3. Remove wheel by removing the alxe.

4. Remove the front fender.

5. there are two bolts under the lower triple tree near each fork. On mine these bolts held on my lowers. They also hold the retaining arms that hold onto the brake line, etc. Remove them.

6. I removed the two bolts holding the headlight on the lower triple tree.

7. I removed the bolts that hold on the turn signals.

8. loosen the top triple tree where it clamps onto each fork.

9. Remove the center bolt on the top triple tree.

10. Remove top triple tree and handlebars, etc. I used a hammer and gently tapped it up and layed it back on the tank.

11. There are two black screws on the lower triple tree. remove those.

12. Slide the chrome covers between the two triple trees on each fork up and off the forks.

13. Remove the plastic "chrome" caps from the top of the fork legs.

14. YOU NEED A FRIEND TO HELP WITH THIS STEP. This is a PITA step to do, but I did it, so it can be done!

There is a brass plate with a large dimple in the middle of it. That plate can be pushed down. You will notice a retaining clip that is holding that plate in. Have a friend use something to push the brass plate down. it will go down between 1/8 and 1/4 inch. probably closer to 1/8. I used the back end of a large cresent wrench.

While your friend pushes down on that.....(He should be holding the fork leg between his legs so that you don't push the front end down and tip the bike over!!!).....use a small screwdriver to remove the retaining clip. THIS is the PITA part. After wrestling with it for a while, I had success by pushing the ring DOWN with the head of a flat blade screwdriver. That allowed me to get the screwdriver behind the ring and I got it out.

Once you have that ring out, the brass plate, being under pressure, will come up and out of the tube and can be set aside. You will see the sping underneath it.

15. Loosen the lower tripleclamp bolt holding the fork.

16. Slide the fork out.

17. Dump the old fork oil and refill before putting in the new springs.

There are instructions on Gadget's page and other places that can help you with details on that, so I won't go into it here.

[NCDave]

A few additional notes regarding working on an 01 1500 Classic.

The instructions from Progressive call for a 4 inch plastic spacer. That IS the distance difference with the old spring.

My fork oil was 6 inches down from the top of the tube. Same in both forks.

I checked both tubes, and the amount of oil in them was just slightly under 16 ounces. I put 16 ounces of oil in each.

Question:

Has anyone experimented with using different oil amounts in their tubes, or with different spacer lengths?

[NCDave]

So if I'm not happy with the feel, removing some oil would soften the ride then, right?

[NCDave]

I'm going to ride them some more before I decide, but first impression is that they seem to be a little too sensitive to the road. I had put some pregressives in a Suzuki VX800 I had and the ride was very smooth. I'd like to eliminate some of the road vitration....I think.

But I don't want it pogoing around on me either.

[NCDave]

Originally Posted by Tom_E

Lighter oil will change things too. Lighter oil will allow the wheel to move faster, lower oil levels allow it to move farther. You have to strike a balance between the two. People frequently go to heavier fork oil when they should have just raised the level. Lighter oil and higher level lets the suspension move freely but will reduce the front end dive under braking.

I used 15W. Any suggestion on going to 10?