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[naitram]

ok, now that i have your attention.... want to make sure i dont actully ruin anything.

i will be removing the forks from the SERK i'm comfortable with this process.

once removed i will be installing progressive mono-tubes.

i have a shop manual but what i dont have is the fancy "fork clamp" tool or the fork seal installation tool.

i seem to recall that you can use PVC pipe to push the seal in, but what diameter PVC pipe?

how do i hold the tube without the "fork clamp"?



the progressive instructions call for 10wt fork oil is there an equivalent i can get at any auto parts store?

[Spiderman]

Neal
       Go with real fork oil. It doesn't cost much. The seal installation tool is nothing more than a sleeve that has an ID that fits over your upper fork tube and an OD equivalent to the OD of the seal. HOWEVER, This isn't something I'd mess around with unless you have the correct tools. You'll end up bunging up a couple of seals. Once you get the entire thing apart, put it back together sans the seal and take it to the nearest H-D indy shop. Buy the seals from them and pay them to install them. The seals are too important to the proper operation of the fork assembly to try to wing it without the proper tools. You've got to buy new seals anyway, so it's not gonna cost you more than whatever the shops minimum charge is to have them installed - - hell they might even put em in for nothing if you buy the seals from them. The rest of it is easy. The hardest part of the whole job is getting the tube assemblies off the bike and back on again. The guts of the tubes are not rocket science but make sure you read the manual and understand how everything goes together BEFORE you begin. Good luck, the old seals are beeeeeeaaaaaaaattttttccccchhhh to get out

B B  

[Chains]

I made my own installation tool years ago out of steel and it is a two piece construction, I would think if you found the right ID and OD PVC you could do the same thing.  Over the years I have put tons of them in for friends, easy DIY job.

[mattm]

Did this very same job recently. Use the 10wt oil.  I bought this seal driver on eBay, it's a pretty decent tool for the price.
http://cgi.ebay.com/ebaymotors/Harley-Davidson-Fork-Seal-Driver-_W0QQcmdZViewItemQQhashZitem2561abd46bQQitemZ160552440939QQptZMotorcyclesQ5fPartsQ5fAccessories#ht_500wt_948

You shouldn't really need to clamp the forks to do the job, just hold them on top of a thick piece of foam on the floor.  Be careful when you open the forks, the springs are under a lot ot tension.  Get all new bushings and seals to rebuild the forks.  If you have one, use and impact to remove the damper rod screws from the bottom of the forks, it helps to keep the rods from spining.

Good luck.

 

[dlaws01]

" Take it to the H-D dealer and pay them to do it "
Just don't take it to my "used to be dealer" unless you want it screwed up somehow.  I'd rather give the neighbor's 10 year old a chance before I go back there!

[naitram]

things were going well, but i've run into 2 issues

issue 1 the right fork leg i removed the nuts, split washer, flat washer but the lower clamp is not coming off

[naitram]

issue 2 i dont have the correct tools to remove the fork caps.

anyone know what i need for this?

[Spiderman]

things were going well, but i've run into 2 issues

issue 1 the right fork leg i removed the nuts, split washer, flat washer but the lower clamp is not coming off

Just stuck from age Neal, take a plastic mallet and give it a few whacks, it'll come off.

B B

[naitram]

issue 2 i dont have the correct tools to remove the fork caps.

anyone know what i need for this?

fire-google-d00d figured this one out for me



For most Big Twin and Sportster models
3805-0013


   
Use for removal of 1 3/8” hex fork cap nut
1/2” drive
Thin socket measures only 9/32” deep by 5/8” tall
O-ring insert to help protect the top of the cap from damaging polished surfaces

[naitram]

Just stuck from age Neal, take a plastic mallet and give it a few whacks, it'll come off.

B B

had at it with a rubber mallet with no luck letting some liquid wrench soak in now

[Spiderman]

had at it with a rubber mallet with no luck letting some liquid wrench soak in now

exactly what are you soaking ? You've got two pieces of aluminum held together by studs with nuts on the ends. You took the nuts off. The cap is just corroded to the bottom of the lower fork tube because you live in Mass and probably ride when there's still salt residue on the roads from the winter. Just whack that bitch and be done with it


B B

[Chains]

Just stuck from age Neal, take a plastic mallet and give it a few whacks, it'll come off.

B B

Slip the axle back in and use the plastic mallet to hit the axle, should come off.

[hdbrad03]

The top Caps are 1 3/8". They just screw into top of the upper fork tube. Get a big ass crescent wrench and loosen them.


 

     Brad

[greglyon]

had at it with a rubber mallet with no luck letting some liquid wrench soak in now

Now if you lived in the great Southwest, where rust and corrosion are as foreign as a good football team you wouldn't have such problems.  

I just put the monotubes in my 2003 flhrsei2 and they improved the ride dramatically.    

[naitram]

took another look at the bottom of the fork leg and think i might have made things worse   will wait till i have the forks out and can see what i'm doing