Just started removing ignition switch to get to the top of the forks to do a fork oil change and half of the threaded part on top of the ignition switch just broke off !!!!!! WTF Not a good way to start a project. I also got to the nuts on the top of the forks and cannot get them loose. Used my 36mm wrench and cannot budge them....either one. On my way out to get another wrench that hopefully will fit on the fork nut a little better. The 36mm did not fit as snug as I would like so I did not want to force it. Not a good day so far, may just go have a beer or 2 or 3 or 4.

Does anyone know what that exact size is......I measured it and looks like 1 3/8". Hate to buy one and not have the right size. Could it be metric ? 36mm just does not fit quite right.

 

i got a 1 3/8 from sears got the caps off with just the fairing and radio removed

 

If you use the 36mm wrench, wrap a rag around the nut to hold it better as it is not the correct size. 1 3/8" is the size you want. As for breaking the plastic threaded part, that's a $57.90 mistake.

 

The bolt is a 35. I broke my switch and managed to hold it together and put the nut on. It's been that way for a long time

 

The bad part about the broken switch is I did not do anything to break it. When I started unthreading the nut by hand I saw something drop to the floor and found the broken pc. I am considering just using gorilla glue on it and see if its holds. Doesn't appear to be a high torque area that holds alot of pressure. Anyone know if I should try to glue it or not.

I did finally get the fork nuts off by using the 36 mm wrench that came with the bike. It was more of a box wrench and grabbed the nut a little better than my open end one did. Fork oil is changed and all is good....except for the ignition switch. Called a local dealer and they have one in stock for $52.00 Might try to get it covered under warranty but don't have a whole lot of faith in that happening since I was doing the wrenching.

 

FWIW, I found this inexpensive wrench at Amazon that I'm using only for fork-oil changes (every 10k miles).

 

and i went the other way and bought the expensive (well, not that expensive) socket.

http://www.killercreekharley.com/esh...NUT_SOCKET.htm

 

Sorry....I was following along pretty good ...then i thought I seen your avatar move....what was your question again? lol.