so i copied your picture, in this picture your bearing is on the stem, did you take it off when you sent it to powder coat? if so how?

as well, any tricks to removing the bushings from the top of the tree?

thanks Ted

 

Maybe it's a model-year difference, but my lower bearing came off the stem without any trouble. That's the new lower bearing you see installed on the stem after the triple clamps were coated. Maybe your bearing needs to be pressed off with a machine press. I think further research about that might be prudent. I wish I could tell you, but I can't.
See post #9 above for ideas on the rubber handlebar bushings.
My powder coater rides and understands that area not coated takes the fork stem nut on top. If it were coated, you run the risk of the powder wearing off and messing with the pre-load on the bearing (tightness of top nut). He was also careful not to coat the clamping area for the fork tubes. Awesome work from Figure Finishing:
http://figurefinishing.com/

 

i guess the bushings are one piece and need to be pushed out, ill try a socket on it with a rubber mallet. i thought maybe the inner metal ring came out. thanks for all the tips you used, i will follow the same for my powder coater.

 

Well heck. You might be right about that inner ring coming out. I didn't think of that. The appropriate size socket sounds like a great idea.

 

bushings done, all complete, except for separating the fork leg tubes, i need a long hex i believe to get the screw out from the bottom of the fork legs to separate them and get the seals out. If anyone knows the size or easiest tool to use, let me know. Pictures below. Thanks Ted

 

Should be 6mm:

 

thanks harleyscuba!