Need help! Anyone removed and reinstalled the fork lower?
Thread Starter
|
Road Warrior
Joined: Aug 2008
Posts: 1,500
Likes: 0
From: Brunswick, OH
Need help! Anyone removed and reinstalled the fork lower?
Or slider, I suppose some call it the fork slider. I'm working on installing my dual brake kit, and I'm stuck on re-installing the new fork slider. I have not removed the fork from the bike, and I'm hoping to not have to.
I've got new oil and dust seals, but I'm having a hard time figuring out how to re-seat the oil seal once the new fork lower is in place. I need some ideas on how to do so.
Here's where I'm at:
As you can see, I have in place the chrome dust cover, new dust seal, then new oil seal, then the spacer and bushings. The fork lower then slides over the bottom bushing, and then the oil seal, bushing and spacer all need to be tapped back into place somehow. I found this website where they made a tool:
http://www.bikernet.com/sportsters/P...asp?PageID=690
Unfortunately I don't have the means to weld anything. Looking for some other ideas. I was thinking about using a wide flathead screwdriver with some tape over the end to prevent damaging the seal. What do you think?
I've got a week to figure it out, since I damaged the upper bushing during the re-assembly, I have to wait for my dealer to get a new one in.
Thanks.
I've got new oil and dust seals, but I'm having a hard time figuring out how to re-seat the oil seal once the new fork lower is in place. I need some ideas on how to do so.
Here's where I'm at:
As you can see, I have in place the chrome dust cover, new dust seal, then new oil seal, then the spacer and bushings. The fork lower then slides over the bottom bushing, and then the oil seal, bushing and spacer all need to be tapped back into place somehow. I found this website where they made a tool:
http://www.bikernet.com/sportsters/P...asp?PageID=690
Unfortunately I don't have the means to weld anything. Looking for some other ideas. I was thinking about using a wide flathead screwdriver with some tape over the end to prevent damaging the seal. What do you think?
I've got a week to figure it out, since I damaged the upper bushing during the re-assembly, I have to wait for my dealer to get a new one in.
Thanks.
Thread Starter
|
Road Warrior
Joined: Aug 2008
Posts: 1,500
Likes: 0
From: Brunswick, OH
Can you elaborate a bit? I was thinking about using a piece, cutting it in half so that it wraps around half of the seal, but then I need a way to tap it without whacking the fork tube.... If there was a piece sticking off of the pipe somehow, something that I could get the mallet on, that would sure help, much like the nut in the picture above.
Although, if it was thick enough PVC I bet I could just tap the edge with the mallet.
Is that what you had in mind?
Although, if it was thick enough PVC I bet I could just tap the edge with the mallet.
Is that what you had in mind?
Road Captain
Joined: Apr 2007
Posts: 583
Likes: 2
From: KC
Remove the fork tube from the trees. Then buy a piece of PVC pipe that will fit over the tube. Take a rubber mallet and tap the pvc pipe until it drives the seal down to where you can get the retaining clip to fully seat. Pop the dust seal in, jam the chromey cap back over the whole assembly, filler up with fluid making sure to compress the fork a few times during the process to remove unwanted air and replace the top cap.
Intermediate
Joined: Feb 2009
Posts: 37
Likes: 0
From: Ohio
I pull the sliders off , then use the bag the seal came in to cover the bushings while sliding the seal up the stanchion. Best tool is a seal driver , but PVC works. Leave the old seal on , above the new seal , and use that as a buffer between the old seal and new seal driver. An FXD can be done in about 30 minutes-both forks.
Thread Starter
|
Road Warrior
Joined: Aug 2008
Posts: 1,500
Likes: 0
From: Brunswick, OH
Remove the fork tube from the trees. Then buy a piece of PVC pipe that will fit over the tube. Take a rubber mallet and tap the pvc pipe until it drives the seal down to where you can get the retaining clip to fully seat. Pop the dust seal in, jam the chromey cap back over the whole assembly, filler up with fluid making sure to compress the fork a few times during the process to remove unwanted air and replace the top cap.
I pull the sliders off , then use the bag the seal came in to cover the bushings while sliding the seal up the stanchion. Best tool is a seal driver , but PVC works. Leave the old seal on , above the new seal , and use that as a buffer between the old seal and new seal driver. An FXD can be done in about 30 minutes-both forks.
Then slide the lower back on over the bottom bushing, and use the old seal to protect the new seal while you bang the new seal and bushings in place. Is that right?
And then you just cut the old seal off?
15 mins a tube eh? How close are you to the Cleveland area?
There'd be a 6 pack in it for ya if you could help me with the reassembly.
Last edited by MZBuckeye; Feb 19, 2009 at 04:54 PM.
Trending Topics
Cruiser
Joined: May 2008
Posts: 142
Likes: 0
From: Cincinnati
Take It Off!!
The easiest way is to take the leg off of the tree. There are tools made for seating the seal, but they can be expensive ($60-75). If this is a one time deal for you, get a piece of pvc. Just make sure it is big enough to contact the seal at its OUTER edge or you can ruin it.
JA
JA
HD Forum Stories
The Best of Harley-Davidson for Lifelong Riders
7 Surprising Harley-Davidson Products that Are Not Motorcycles
Verdad Gallardo
8 Best Harley-Davidson Motorcycles Ever
Pouria Savadkouei
10 Worst Harley-Davidson Motorcycles Ever
Pouria Savadkouei
Killer Custom's Jail Break Is The Breakout That Refused to Blend In
Verdad Gallardo
Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?
Verdad Gallardo
Harley-Davidson Reveals Super Cool Cafe Racer Concept
Verdad Gallardo
Engraved Rebellion: Inside Bundnerbike's Glam Rock II
Verdad Gallardo
10 Motorcycles You Should Never Buy
Joe Kucinski
10 Things Harley-Davidson Needs to Fix in 2026
Verdad Gallardo
Road Captain
Joined: Apr 2007
Posts: 583
Likes: 2
From: KC
I'd just pull em off cause you're still gonna have to take the top cap off in order to fill them with fluid. If they're still on the bike you run the risk of dumping fork fluid all over the bike if something goes awry. Do it however, but in my experience its easier to just pull the whole assembly.
