Contemplating gaiters last November, I asked resident BA/SM design guru Brent about installation. Here is what he was kind enough to send me. I'd suggest we alter a page out of Henry Ford's playbook and each one of us get really good at one thing. Then when a member needed that thing done, they'd consult the "thing" directory and go for a spin to the respctive members' place. That way you get the one thing done correctly and also get a great ride out of the deal. Being a certified generalist, I don't know a lot about any thing, but some thing about many things.
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courtesy newspeedmaster
Fork Gaiter Installation Instructions
1) Remove the fork legs per the Service Manual instructions. You will have to safely raise the front of the bike, remove the wheel, brake caliper, speedo cable and front fender. Tip; it helps a lot to remove them if you remove the headlight bolt on the leg you're removing. DO NOT remove the top cap! Also only remove one at a time and replace it before taking the other one out. Take your time, do not use pliers or other devices, it will break free but will be very hard at first. A strap wrench is useful if you have one...
2) Remove the plastic rock guard. You will probably have to pry a little - a heat gun or blow dryer will help in softening this up. You can also use a soft wood block to "drift" them off from their retaining grove.
3) Spray the fork tube with WD-40, LPS or other light lubricant. Slide the gaiter (boot) over the tube and seat the large end over the lower fork legs & seals. The boots are a tight fit, you may have to either dip one end into hot water, use a heat gun or WD-40, to soften the vinyl so it will slip over the grooves that the plastic "protector" clipped into. The other end sits snug in place;
4) Replace the fork leg back into the triple tree and headlight bracket and torque the clamp bolts to 27 Nm. After replacing the headlight bolt, repeat on the other side. Then reattach the fender, wheel, brake caliper and speedometer cable.
5) Last use zip ties at the top of each tube just under the lower triple tree. You should also use the included zip ties for the bottom as well. Make sure you get the vent holes in the boots facing rearward.
