I changed the oil on my 97 1200 custom but having a hell of a time trying to put washer, spacer, and cap back on. The spring sticks out and I just can't seem to push hard enough to even get close enough to tighten the nut. I have the front lifted off, is there something else I need to do? Please advise.

 

I've heard they can be a real pain in the butt. I've read of several ways to do it. I cannot recall the best technique, but one of the members should be able to help.

I bought caps with a threaded plug and had my local indy install them. Now, I just have to remove the plug to refill fork oil, no messing with the springs. You might think about that before you re-install the OG caps.

John

 

Yeah, it's a grunt. Helps to use a socket with a strong friend pushing down while you tighten. I had to do it myself but I had the tubes removed. I made a contraption that kept downward pressure on the plug while got it started.

 

I usually take the spring out, then thread the cap on. I note the relative position of the cap to the forks when the threads just start to grab and mark that spot on the cap with a marker or piece of masking tape. Then, when I've gotten the spring in, I rotate the cap so that the mark on the cap is just a bit ahead of the place where the threads engage before I start pushing down, then start turning the cap. It usually takes a few tries to get them in but it seems to work pretty well. Once you've got about a half-turn in with the threads engaged you don't need to push down any more.

 

Getting that cap back on can be a real PITA. I struggled with my 05 Super Glide for 30-40 minutes before I got them to screw on. There's got to be a better way.

 

Take it to your local indy, like I did.

John

 

What I do is screw the cap on without the spring and mark the spot were the threads catch with a sharpy (make sure you mark the tube and the cap) that way when you press the cap down the threads will catch, take the fork off the bike and try and get the slider secured and when you push the cap down (On your mark) turn the fork tube (not the cap) to thread it on, also a thick leather glove on the cap hand helps

 

Maybe the forks on my partners 2008 Custom isn't right then as I was able to put the caps back on single handed.

 

I use a 'repurposed home made tool' for this. It is a large furniture/wood clamp,
a large spacer, and a bearing on top of a socket wrench. Here are some pics....







I did not do this, but for safety, I would recommend securing the lower
part of the clamp so that it won't slip off of the triple tree.

hth,

T.

 

That's the method I recall seeing, nice work.

John