Easiest way to replace fork boots - R80st

[bmcdonou]

Hi all,

I need to replace the fork boots / gators. I'm looking for the easiest path - from the top or from the bottom. In reviewing the manual, both paths seem quite involved.

From the top, it seems I have to remove the dampener knob, ignition, handlebars, turn signal repeater (haven't located that yet)... I assume to have enough clearance to remove the top nut. I can get purchase on it and loosen, but I suspect based on the pics it's too deep to clear everything and come all the way out.

From the bottom, it seems I'd potentially have to replace the seal, and apparently requires special tools to install and to get the slider back on the post (none of which I have). I don't want to go that path and get stuck for a week waiting for parts.

The seal is not leaking and the forks are otherwise fine and operational, and so I have no interest in going places I don't have to go. Is the manual being overly cautious? Is there a trick to do this easier and avoid a waterfall of parts, tools, and work?

 

[20774]

For me, I'd work from the bottom for my /7...I've had to do that at least once. But the ST is a bit different.

Brook Reams has a section on the front end rebuild on an R80ST. Maybe there's something instructive there:

31 BMW 1983 R80ST Remove Front Suspension

Here is the bike after removing the wheels and the handlebars. I’m ready to remove the front forks, steering stem acorn nut, top plate, steering stem pre-load nut, chrome dust cover and the s…

brook.reams.me

 

[olironrider]

There is no easy way !
It always help us, if you state the motorcycle you’re working upon ?
Where are you located ?
Working from the bottom of the forks has less chance of disturbing fork alignment.
What is your skill level, tool situation, work space set-up ?
Regardless, you’ll need some crush washers, fork oil, and 6-8 hours of labor for a first timer ?

 

[bmcdonou]

There is no easy way !
It always help us, if you state the motorcycle you’re working upon ?
Working from the bottom of the forks has less chance of disturbing fork alignment.
What is your skill level, tool situation, work space set-up ?

R80st. It's in the subject line.

Moderate skill and experience. I've had a vintage bikes for 5 years, but new to bmw. Garage, most tools except for any specialty bmw tools.

Alignment is what I initially was trying to avoid. It's not mentioned in the Haynes manual at all (that I could find), but I did watch Brooks do it on his r80st build and it looks like something to avoid.

In going from the top down, my plan was to reinstall the axel, leave fender and everything attached, mark the orientation of the tubes so that they could go back in place the way they came out, slide both down together, slide the boots on, and right back up.

From the bottom, the book talks about special tools to install the new seal and to install the sliders, both of which are a about $50 each....so then it's getting expensive. Unless I can avoid them all together and use a large socket to install the seal and something else for the sliders....otherwise, figured top down might actually be the best.

Just feels like a lot to remove. If there is no shortcut, then I'll just have to bite the bullet one way or the other.

 

[6322]

I’ve done this several times on the ST, from the bottom. Pretty straight forward, no special tools.
you might consider doing the fork seals at the same time since you’ll have easy access to them doing the process. Getting the fork tubes back in and lined up, getting the fender brace and fork brace adjusted properly and equal amounts of fork oil in the tubes will be the challenges. If you don’t remove the fork tubes you shouldn’t have to worry about getting them lined up.