Fork Chrome Cap

[zoom45]

I was going to change my fork oil today. Does the chrome cap over the fork tube just pry out with a little pressure using a screwdriver or do you need to loosen the bolt clamping the tube? I pried on it a little but it doesn't seem to move and I didn't want to damage it. I thought it was just a plastic cap stuck in it like the handlebar bolt covers. :-/ Or, is the chrome cover over the forks all one piece with a rounded top frome the lower part up to the tree?
It's a 1500 Nomad:


Thanks,
Zoom45

[strobe]

You need loosen the pinch clamp and then use a 22mm (I think that is the size) socket to remove it if I am thinking about the same cap as you.

[Jared]

Kinda bring up another question, but when do you need to change your fork oil?

[zoom45]

The manual says change it every 2 years or 15,000 miles.

[strobe]

Originally Posted by zoom45

I was going to change my fork oil today. Does the chrome cap over the fork tube just pry out with a little pressure using a screwdriver or do you need to loosen the bolt clamping the tube? I pried on it a little but it doesn't seem to move and I didn't want to damage it. I thought it was just a plastic cap stuck in it like the handlebar bolt covers. :-/ Or, is the chrome cover over the forks all one piece with a rounded top frome the lower part up to the tree?
It's a 1500 Nomad:


Thanks,
Zoom45

I see you added a picture....

I did not notice that it was a 1500 before. I would loosen the pinch bolt first, with the pinch bolt tight there is a pressure on the fork tube so the cap is likely much tighter than most bolt covers would be. Here is the exploded parts view for a '04 Nomad 1500 front fork and it shows the cap (11012).

[zoom45]

I took the pinch clamp bolts out opened it up some and still can't get the caps loose. Anyone know a trick to this? They must be deep caps. I can't see the bottom of the cap through the slot in the pinch bolt slot.
Thanks,
Zoom

[strobe]

Sorry, I can't help you there. I don't have a 1500 to try it on...

[perryco]

Mine popped off - I didn't have to loosen the pinch bolt. You just need a small screwdriver, some pressure, and a little patience. It is a fairly deep cap, and if it's been a while since it's been removed, it might be sealed in there pretty good. Loosening the pinch bolt should've done the trick in that case. Maybe just a touch of lubricant to loosen it? (careful on what kind - don't want to mar the plastic)

[zoom45]

I thought the cap was recessed deeper into the tube but it had such a good fit on top of the tube, I couldn't see the seam in it. (I can't see very good up close anyway). I took a knife blade and separated it. I guess I'm use to every project having some unexpected difficulty to it. I wasted a lot of time thinking it was harder than it was. The plastic cover has only about a 1/16" showing and it's all above the pinch clamp. It's made like the bolt covers and just slips in with a press fit. Nothing like learning it the hard way. LOL Now I can change the fork oil.
Zoom

[dogdoc]

how really bad does fork oil go??? I've got nearly 4 yrs and same oil. thats not something alot of people jump on, or should we.??

[zoom45]

The manual says change it every 2 years or 15,000 miles. I had some time to work on it so I said what the heck maybe the ride quality has decreased (60,000 miles on same oil) so I'll change it and see if it improves. Can't hurt plus I'll learn how to do something else on the Nomad. I'll know better next time I need to do it or hopefully can save someone else some trouble.
Zoom

[ringadingh]

I don't change it that often if the front end feels ok to me. However on my Nomad I find the forks to soft and mushy for my preference, I found that my bike dives easily when braking. To help cure this a heavier weight fork oil should be used. Our Nomads come with 10 weight oil from the factory. Most guys seem to replace it with 15 or 20 weight oil. I put in 15 weight and wish I had used 20 weight.

[redjay]

Hi, I had my fork springs replaced and valve modulators installed (Racetech Products) by a local shop that specialises in suspension. They were better, but expensive at $600. It took some of the harshness out of the forks when hitting a bump.

[zoom45]

I just finished mine and fixing to take it for a ride. I took some pictures during the process so if anyone needs a "how to" with pictures let me know. The article on Gadgit's page is right on how it works. The only thing that takes so long is the aquarium tubing will only pick up so much oil so it takes several times with the syringe to suck it out. I tried to extend the tubing and make it gravity flow to the cup but it wouldn't work. I removed 356ml which is what the manual said it had in each fork. A one Liter bottle of fork oil is enough to do both forks and have a small amount left over. I used 15wt oil. Total cost - About $12 for oil and aqaurium tubing.
Zoom45