[Vic01]

Hi, recently acquired abovementioned RE. Amongst other repairs, I am in the process of trying to replace the fork seals. Please forgive me for my ignorance. I have consulted the manual, but it does not make sense to what I have. I have scoured youtube for tutorials, but none seem to apply to what I have. Can anyone enlighten me? I have attached some pictures. The first three are the top, middle and bottom of the fork. The 4th pic is blurry, but it show the bottom with the oil plug removed, and nothing inside that hole to indicate a fastener. I would appreciate your wisdom and guidance. Thanks.

[Haggis]

Looks like normal early style forks.
Once you undo the bottom nut the fork leg should pull apart.
Once apart,  be very careful when levering out the old seals. It's easy to damage or break the top of the alloy leg.
There is a tool that one can buy that fits over the top to protect it.

[Vic01]

Thanks for your reply. The bottom nut screws out, which I believe allows the oil out. But the fork does not appear to come apart. I must be missing something.

[Adrian II]

The G5/Electra-EFI models were the last with the old-style fork, in which case these technical notes should apply. If the fork sliders won't come off it could be because they're a bit of a tight fit on the damper tube.

https://accessories.hitchcocksmotorcycles.com/core/media/media.nl?id=188643&c=1062795&h=c7973cdc2e91f90447bf&_xt=.pdf

A.

[Haggis]

Thanks for your reply. The bottom nut screws out, which I believe allows the oil out. But the fork does not appear to come apart. I must be missing something.

As Adrian says, the damper tube may be a bit tight at the bottom of the leg.

As Hitchcocks guide says,
. The alloy fork ends should then pull down and off,
but you may need to give them a little encouragement with a
rubber mallet if the spring stud is a tight fit in the alloy.
Once removed be aware that there is a loose “oil control
collar” on the end of the fork spring stud. This may drop off,
or may have already fallen down in the alloy fork end.

[Vic01]

Thanks for that. So the bottom plug is out, and that doesn't seem to be fastened to anything. I have tried to use the chrome tube to hammer itself out but it really feels like it is hitting something solid. I have restored many cars in the past so am not a newbie with mechanicals.  This is my first motorbike and I am just being cautious,  as I don't want to damage anything.
So you reckon with just the drain plug out, the chrome tube should come away from the sleeve? What does the drain plug attach to? I've attached a photo. Does the thread that the drain plug is attached to push into the tube? I've tentatively smacked it with a hammer (with plug on and with a piece of timber) but it feels solid. I just don't want to blindly rush in and break something.
Please forgive my ignorance.

[Haggis]

Yes, that bolt screws onto the bottom of the damper tube.
Rather than hit the bottom threaded part, which should go up into the fork. Try pulling the fork tubes apart, like a slide hammer action.
A bit of heat on the alloy around the area may help it let go.
https://youtu.be/kMO7wKlDiVU?si=ziKJB1MwSFoxFhZs

[Vic01]

Thanks so much for patience and wisdom. It had me stumped, as that threaded part appeared solidly fastened. Even my mechanic friend wasn't sure. I will get to it today. Cheers.

[Vic01]

Thanks so much. Application of some heat and it pulled right out. Much appreciated.

[Vic01]

Now that it's out, I found this pitted section. Right where the seals are. Do I do something about this? Will it score the seals?

[Haggis]

No point in refitting with new seals, as you say, they will get damaged from the pitted leg.
You can have then re chromed or easiest solution is a pair of new stantions. probably cheaper than a re chrome as well.

[Vic01]

Ok, thanks for that.