I dropped the forks this evening to install some Progressive monotubes. I popped out the fork lock in order to remove the dash panel so I could access the pinch bolts on the triple trees. While I was loosening the triple trees I turned the forks to the left and the locking mechanism engaged. I stuck the lock back in, got it unlocked and finished the install.

Now, if I turn the switch lever to the "Lock Forks" position and turn the bars to the left the lock pin drops in without having to push the lever down. When I turn the lever back to the Off, Run or ACC positions it disengages the lock so it doesn't seem to be a riding issue...I hope....I don't use my fork lock very often but if memory serves the lever had to be held down to engage the fork lock and then you had to use the key to hold it in the locked state. Unlocking the key allowed the lever to pop up unlocking the forks.

 

Sorry I can't help you with your fork lock problem but just some insight for the future. I know the manual says you need to remove the fork lock/ignition switch to remove the dash panel but the manual is wrong, no need to mess with that. It takes a little finesse but the dash panel comes off without fine without messing with the switch. I've had my dash panel off many times and never messed with the switch. Hopefully someone will chime in as far as your fork lock issue.

 

Did you replace the spring in the fork lock?

 

Does not have to be pressed down. The only time it gets pressed down is when it is locked by key.

 

Yes. The spring is installed and seems to be operating properly,

 

OK then. As I said I rarely use the fork lock. I think every time I've used it I have turned the bars to the left first and then turned the handle to the lock position, pushed it down and locked the forks. I don't recall ever placing the handle in the lock position first and then turning the bars to the left before this evening. Thanks for the info.

 

I had the same problem when I did mine. You have to align all the parts in the lock, then drop your tumbler into place. I used a long thin screwdriver to align everything. Hope it helps.

 

When you had the ignition switch out and the bars went to the left and locked it turned the mechanism down in the neck. it is kind of a PIA but like said above you have to take something like a long thin screwdriver and keep playing with the mechanism until everything lines up.

 

Hope this helps:

 

Thanks for all the help gents! When I get home this evening I'll pop the lock again and see if I can get everything lined up properly.