A big screwdriver threw the caliper mounting bolt holes works for me to keep the leg from turning....provided your leg has those holes.

 

I tried to get the OEM onto the chrome slowers but I gave up. But I might not have been beating it too much.

 

Using the stock dust caps would prob'ly solve the problem. I didn't anticipate any issues when I did my changeover, so I didn't see if the stock caps would fit the new chrome lowers...just wanted to install all the new shiny pieces! It would be pretty easy to pull the caliper, loosen the tree pinch bolts, slide the front end out'a the trees and try the original caps. I like the look of the bigger caps; goes well with that massive looking brace. But it may look fine with the originals, too.
If you beat me to it, let me know if the old caps fit the new chrome lowers.

 

You got a pic of the brace on the chrome sliders? Also where to get one? The number did not come up at Zanotti's.

 

I'd love to do it asap but I'm going to collect a set of Intiminators and new fork springs first. Take it apart once. May be a few weeks before I get to it. I really am starting to see how crappy this bike handles. It sorely needs improvement.

 

god info...

 

Just had another thought for those that may be doing this in the future. If you have a fork brace, leave it on. It will stabilize the lowers so you can loosen the 12mm drain bolts at the bottom of the lower. Once loosened, remove it to continue the job at hand.

(I have the strangest thoughts at work.)

 

Airborne;
I'll try to get a picture in the next few days. I think HD has discontinued the 49mm Wide SE Brace (43466-06?). You'll occasionally find one on ebay or here on the Forum Classifieds.

 

You can also use a padded crescent wrench on the slider down where the axle goes.

Or take the whole tube assembly off the bike and clamp that same lower portion in a bench vice, padded of course. Removal from the bike makes it easier to drive the seal back in, as well as less jarring through the bike while trying to separate the lower from the tube. Plus you can measure the fluid height too.

 

Well, I skipped a nice riding day in favor of tidying up some loose ends. Turns out that my left-Lower had a manufacturer's defect. There was a 2nd shelf or ridge about 1/8" above the machined shoulder that separates the "show" part of the Lower from the part covered by the DustCap, and into which the dust seal fits (tried pix but shiny chrome prevented success). I ended up wrapping the top edge of the "show" part in multiple wraps of clear packing tape (right to the edge of the shoulder), and hand-filing to remove the mini-shelf that was keeping my new DustCap from fitting all the way down to the correct shoulder. Used a slow & steady hand, holding the file flat with the correct shoulder acting as a guide for its edge. I filed thru the ridge until all traces of copper plating were removed. Fortunately, the ridge wasn't a full 360 around the Lower, only about 230-degrees and offset like the lobe of a camshaft.

With the DustCaps on correctly and the front end out'a the trees, I used the opportunity to re-install my SE Fork Brace (Airborne; correct number is 46634-06 for '06+ Wide [discontinued]). HD said that it wouldn't fit with the Chrome Lowers Kit; also said the Kit's Billet DustCaps wouldn't fit with the Fork Brace! By defying their wisdom, I fully expect to suffer "Loss Of Control, Leading To Death Or Serious Injury", but I'm willing to roll the dice. With the DustCaps fully seated and Blue-Loctited, I loosened the underside screws of the Fork Brace and angled it in between the Chrome Lowers. I had just enough room with the Brace against the tire (fender removed) to angle it up and into position, then flushed it up against the bottom edge of the DustCaps. Tightened the four underside screws, then bolted on the outside half-circle clamps around the top of the lowers...beauty! After tightening the front end back up into the trees and re-installing the caliper, I also added the Fork Tube Caps that came with the kit (pix in following post). Didn't install the matching Stem Nut Cap, 'cuz I couldn't fig'r out how the stock one comes off (anyone know?)

I haven't re-installed the fender yet; gonna have to slot-out the four mounting holes UP, so the fender can sit closer to the tire and clear the Brace. Vic; I noticed some stamped-in "targets" on the bottom backside of the Chrome Lowers. I'd bet a dollar to a donut this is where you're meant to drill and tap for drain screws...I'd recommend you do it before your install.

One other thing; While I had the new DustCaps off, I tried the stock ones on the Chrome Lowers...no go. But the stock Caps WOULD slip inside the new Caps, to the distance of a machined shoulder (about 5/16" inside the new Cap), that's meant to abut the shoulder machined into the top of the Chrome Lower.