OK, so I had to take a spindle of the front of the pilot to fix, I had to use a fork to get the upper ball joint apart and damaged the dust cover, is there a replacement or am I SOL?

PS is there a thread for alternative parts for Pilots and Ody's?

As you probably have figured out by now the fork tool is a DESTRUCTIVE tool it was meant to be used on parts you were removing and throwing away, I strongly suggest you take the fork and throw it in the garbage its a tool you should have never bought in the first place, keeping it in your garage will just encourage you to do more damage in the future to something else, its a tool that should come with a big sign saying USING THIS TOOL WILL TURN PARTS INTO JUNK not that it would keep people from using it lol.

Their are other easier NON destructive methods to remove a ball joint and not damage anything.

Do a search for ball and joint and boot everything in the bold letter including the AND their has been a lot of discussion about this in the past here is one viewtopic.php?t=237&highlight=ball+joint+boot

Ya, I knew it was destructive when I gave up on the method on whacking a through away nut, Could not get a good shot at it and was not working on the bottom either.
I really did not think it would be so difficult to locate a replacement. whent to the local honda dealer, it looked like the seal on a TRX450 was about the same, they don't sell them for those either.
Going to call the local honda auto dealer to see if they have any in stock. P/N 53348-611-310
Thanks,

Soak it in PB Blaster for a couple days, then use a Big hammer on the arm and end and hit it, it will break.I would look at the trx 450r arms as well for replacements on the boots.

Bike bandit has replacement ball joints for less than $20/side, upper and lower. that may be the direction I head for the seals but I'll look at the auto parts store "help 13561" item tie rod dust boot.

Replacement ball joints?? Your going to cut out the old and weld in the new?

No, I'm just thinking to buy the new ball joints, remove the dust seal and use it on the pilot.

opted to go with the $4.99 fix from Autozone, item # 13566 in their help section, found it through the link that you had posted earlier. it seems to work good, I pushed it on further that the step that the original boot fits as that was sort of loose.

Just an update on the "super glueing" of the ball joint covers. Its been 6 years since I glued my covers on and none of the 6 covers I installled have ever come loose.

That's good news as I acquired everything I needed to replace the boots on one of ours and glue them up in February, but never got around to it.