This issue has come up before & you’re an easy trick away!
Once the lower tube & lower leg are off & apart, you are left with...
Removing the hex screw that holds the dampener/seal in the bottom leg. Removing this will remove the dampener/seal inside the fork tube & allow you to install the Progressive kit.
Trick:
1. Get a small broom stick & insert it ALL THE WAY into the tube so it bottoms out against the dampener plunger. (This is where most people mess up)
* Issue Tip: make sure the fork is fully extended!
In some cases the forks can "get stuck" & you will not be able to remove the hex screw unless fully extend.
* If so: keep compressing & expanding (leg & tube) by hand (sharply & abruptly) until they reach FULL extension.
2. Put the stick on the ground with the fork inserted over the top of it (lower leg with hex nut facing up).
3. Put pressure on the tube so the dampener does not spin while you remove the hex nut from the bottom lower leg.
It should be as easy as that...be patient unscrewing, as it will feel like nothing is happening.
Warning: Do Not use a high speed tool for this install...you can cook the seal on the dampener plunger. Seal is $80. As it comes on the plunger OEM. Only
Last: You may have to jiggle the tube to get the plunger & lower leg apart after removing the hex nut.
4. Reverse & repeat for reinstall.
I noticed this issue is causing people to "give-up†or question the whole installation. Believe me its WAY worth installing the "whole" Progressive front end kit the "right way". U WILL B HAPPY & notice the improvement.
Just stick with it, it's a little tricky but if you do it once you'll be a pro @ this.
Member
Gary James
* Feel free to email me for my phone info if you need support
