1993 FLHTC Front Fork Rebuild
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Cruiser
Joined: Jul 2009
Posts: 141
Likes: 62
From: Vermont
1993 FLHTC Front Fork Rebuild
I hit a large pothole lurking in the shadows of a very poorly maintained road and I think I broke something in the front end suspension...so the forks need to be disassembled and inspected. I've changed the fork oil, on schedule, over the years but have never had to dig into the front suspension any deeper. Any tips or trouble spots I should be aware of as I pull it apart? Also, the air suspension is no longer holding pressure. Is there a common spot for that system to fail? I have the FSM and will start tearing into it tomorrow. Thanks in advance for the help.
Last edited by eglide_vt; Sep 21, 2019 at 01:49 PM.
Seasoned HDF Member
Joined: Jul 2014
Posts: 8,590
Likes: 3,360
From: Cental, MI
Called "bottomed out" ... **** happens... Never hurt mine... heck!! look how tightly some folks tie them down when hauling!!!
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Cruiser
Joined: Jul 2009
Posts: 141
Likes: 62
From: Vermont
I appreciate what you are saying, but Ive been riding this bike for 25 years. I know every sound it makes and something has changed in the front end. I appreciate the replies but Im really just looking for tips or things to be aware of as I disassemble the front end. Thanks.
Ultimate HDF Member
Joined: Jul 2014
Posts: 5,649
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From: MASS_hole
I wouldn’t be surprised at all if you find that the lower tree might have cracked over by the pinch bolt.
Check the steering neck and down tubes for fractures. Highway bar.
Forks will bend. Even the slightest is enough for internals to scrape/rub. Sometimes eye balling it is nit enough. Very tight in inside the forks. Gotta come off. But first check the hangers. Use bright lights and a magnifying glass.
Good luck bro
Check the steering neck and down tubes for fractures. Highway bar.
Forks will bend. Even the slightest is enough for internals to scrape/rub. Sometimes eye balling it is nit enough. Very tight in inside the forks. Gotta come off. But first check the hangers. Use bright lights and a magnifying glass.
Good luck bro
Road Warrior
Joined: Dec 2010
Posts: 1,268
Likes: 507
From: Florida
My contribution:Change the front springs out and omit the air ride. There is an anti dive valve assembly that probably isn't working any how. Could be why the front doesn't hold air. All you need to do is get a couple bolts to plug the tapped holes in the top fork bolts.
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From: MASS_hole
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Joined: Jun 2007
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From: Bedford UK
For piece of mind it makes good sense to overhaul your forks and do a complete strip down. If you haven't done so before you may be surprised how much filth accumulates inside the sliders! If you do away with the air, replace the springs, as they are not man enough on their own. At the least use single-rate springs, matched to your weight, such as from Race Tech. Also consider adding Ricor Intiminators, to improve ride quality.
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