Front fork rebuild question
Club Member
Joined: Jun 2007
Posts: 45,429
Likes: 2,898
From: Bedford UK
I've just replaced my forks and seals on a 2004 harley sportster xl 1200 custom. At the top of the forks (where the cap screws on) one of the springs is flush with the top, the other spring sticks out a a few inches. What am I doing wrong? Any help is greatly appreciated.
Thread Starter
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4th Gear
Joined: Oct 2016
Posts: 8
Likes: 0
From: Texas
I think you're right, I tried to post pictures but it wouldn't let me. The pieces of metal were very small square pieces and the spring was maybe an inch around and half an inch tall. Can these pieces be replaced or is the fork useless? Just paid $200 for the set and don't really wanna do that again.
Grand HDF Member
Joined: Dec 2014
Posts: 4,890
Likes: 553
From: USA
The fork is made well and doesn't just break apart so look for the pieces in question in this diagram. It will give you an idea on what you need to do to put it back together...probably just came loose.
http://partsfinder.onlinemicrofiche....TEERING%20STEM
http://partsfinder.onlinemicrofiche....TEERING%20STEM
Stellar HDF Member
Joined: May 2007
Posts: 3,256
Likes: 522
From: USA
In for answer.
"Replaced forks and seals" seems confusing as the seals should already be installed with the forks. Or did the OP mean sliders and seals?
First confirm sliders and springs are the same length.
Second, I think as mentioned above, something is broken inside the fork or the fork is assembled incorrectly.
Again in for answer.
Good luck.
"Replaced forks and seals" seems confusing as the seals should already be installed with the forks. Or did the OP mean sliders and seals?
First confirm sliders and springs are the same length.
Second, I think as mentioned above, something is broken inside the fork or the fork is assembled incorrectly.
Again in for answer.
Good luck.
Thread Starter
|
4th Gear
Joined: Oct 2016
Posts: 8
Likes: 0
From: Texas
In for answer.
"Replaced forks and seals" seems confusing as the seals should already be installed with the forks. Or did the OP mean sliders and seals?
First confirm sliders and springs are the same length.
Second, I think as mentioned above, something is broken inside the fork or the fork is assembled incorrectly.
Again in for answer.
Good luck.
"Replaced forks and seals" seems confusing as the seals should already be installed with the forks. Or did the OP mean sliders and seals?
First confirm sliders and springs are the same length.
Second, I think as mentioned above, something is broken inside the fork or the fork is assembled incorrectly.
Again in for answer.
Good luck.
Last edited by Catto95; Nov 1, 2016 at 12:42 PM.
Club Member
Joined: Jun 2007
Posts: 45,429
Likes: 2,898
From: Bedford UK
Yes, sliders. Sorry this is my first bike, and the first time working on a bike. Inside the slider is where I found the broken chips of metal, and the loose spring, also the rod that drops into it (damper? Not sure. #23 in the picture above) comes out a lot farther at the end than on the other slider. This also leads me to believe something is broken inside the slider. And yes, the sliders and springs are the same length. Thanks.
Last edited by grbrown; Nov 1, 2016 at 01:26 PM.
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Thread Starter
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4th Gear
Joined: Oct 2016
Posts: 8
Likes: 0
From: Texas
The part I'm talking about isn't on the diagram. It's inside of the slider tube, at the bottom where the slider bushing goes. I've looked inside the old slider and it looks like the spring, then the 4 metal pieces holding the spring down. These metal pieces broke off of the sides so there's nothing holding the spring from falling out.