Fork Lug Removal

[Falkonworks]

Has anyone here ever removed the lugs from front fork inner tubes? I am needing to do this and have seen only a couple videos on YouTube showing the process.

Really only one was worth anything and you can watch it HERE if you’re interested.

What I noticed in his video is that his forks do not have the same adjustability that our Hayabusa’s or any of the new sportbikes would have with adjustable compression in the lug. I have never messed with this adjustment and can’t pretend to know anything about it.

I’m looking for anyone who has experienced tackling this job to chime in and let me know if there is anything else I need to be aware of before trying to tear these apart. Any help is appreciated.

 

[sixpack577]

The compression adjuster comes out of the lug, it's held in by threads and/or a set screw.
I have taken those out, never removed the lug itself, but with the adjuster out, the lug will come off just like in the video.
I have seen the lower fork legs be disassembled for replating.

 

[Kiwi Rider]

I think from memory ( I was told about this years ago) the correct method is to anchor the chrome plated inner fork tube (stanchion) in a vice ( using the 2 holes at the top of the tube to secure it) and heat the ‘lug’ up to expand it and melt any threadlocker that is applied.
The tube is threaded into the lug so put a bar through the axle hole in the lug, or you could use the axle itself, to turn and unscrew the lug from the tube.
I’ve never actually done this job, but I was told by someone that has… so this is hearsay. Best to research it yourself lol.

 

[Falkonworks]

The compression adjuster comes out of the lug, it's held in by threads and/or a set screw.
I have taken those out, never removed the lug itself, but with the adjuster out, the lug will come off just like in the video.
I have seen the lower fork legs be disassembled for replating.

Ok. I was hoping this would be the case but just didn’t know for sure since I can’t find much information.

I’m thinking I might take some photos and document the process and post it on here in case I run into any issues, or if I don’t, it’s just good information for anyone else doing it in the future. I stripped one of the axle pinch bolt holes. I already had plans to take some weight out of the lugs, so instead of using a helicoil or making the bolt hole larger I’m just going to swap the lugs from my spares and modify them while the forks are disassembled.

 

[Falkonworks]

I think from memory ( I was told about this years ago) the correct method is to anchor the chrome plated inner fork tube (stanchion) in a vice ( using the 2 holes at the top of the tube to secure it) and heat the ‘lug’ up to expand it and melt any threadlocker that is applied.
The tube is threaded into the lug so put a bar through the axle hole in the lug, or you could use the axle itself, to turn and unscrew the lug from the tube.
I’ve never actually done this job, but I was told by someone that has… so this is hearsay. Best to research it yourself lol.

That’s pretty close to how the guy in the video did it. I ordered a clamp for the tube and when it gets here I’m gonna give it a try!