Harley Fork Rebuild - Not riding now :-( - Chicagoland Sportbikes
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post #1 of 15 (permalink) Old 05-04-2010, 07:39 AM Thread Starter
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Harley Fork Rebuild - Not riding now :-(

I would love to be out riding today, but the dam Harley decided it would be better to sit in the garage. The left fork started leaking fork oil, so I decided to go ahead and rebuild the forks. I got the rebuild kits yesterday. Here's the kicker: It's not even leaking at the fork seal. It's leaking at the joint of the fork cap that has a captive o-ring seal...WTF!

Long story short...

I pulled the outer fairing to do a few "quick things" but then I had to pull the radio out when things didn't go as planned. That's when I said screw it, and just started tearing it apart. The first pic is what's behind the outer fairing, and the second pic is where I stopped last night.

I really like the look of all the chrome crap on the Harley, but it's a PITA when it comes time to work on it.
Attached Images
File Type: jpg HD-Forks2010 003.jpg (72.7 KB, 32 views)
File Type: jpg HD-Forks2010 006.jpg (86.8 KB, 38 views)

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post #2 of 15 (permalink) Old 05-04-2010, 08:06 AM
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Can't you just remove the caps and install new o-rings?

Steve
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post #3 of 15 (permalink) Old 05-04-2010, 09:51 AM Thread Starter
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Quote:
Originally Posted by SL954 View Post
Can't you just remove the caps and install new o-rings?
Yes, once you remove the forks.

There's a air fitting/banjo bolt that goes through the upper tripple tree into the top of the fork cap. You still have to lower the fork to remove the fork cap since it's UNDER the upper tripple tree. I'll take some more pictures tonight, and it'll make more sense.

Hey Harley!

Even if you lower the fork enough, the cap is under spring tension (slight), and trying to get it back on while working within the fairing area between the upper and lower triple tree would be a pain in the ass.

If this were on the gixxer.........it would be a 15 minute job.

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post #4 of 15 (permalink) Old 05-04-2010, 04:14 PM

 
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please strap that sucker down bud! see for me GSXR's would take a bit more time and the HD would go faster! let me know if you need any help or have any questions

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post #5 of 15 (permalink) Old 05-05-2010, 08:09 AM Thread Starter
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All Done!

I took a 1/2 day off of work yesterday to work on the bike, but ended up spending most of the afternoon just getting supplies and and a couple of tools (1-3/8" wrench I'll never use again). I finally got the forks out and disassembled. There's really not a lot inside of the older air suspension forks.

I replaced all of the bushings and seals. The one thing that struck me as odd, was the lack of dust seals on the forks. Maybe they didn't use them in 2000. Oh well, they're on there now.

The hardest part was getting the fork cap back on. The progressive springs are a bitch the compress with the cap while you're trying to turn it and engage the threads. I ended up going inside and I got my wife to hold the inner tube up while I did the rest. The sad part is that I had her in the kitchen, on her knees in front of me, and I didn't even take advantage of it.

I got the bike back together around midnight. I was on a mission. I rolled it out and played SQUID as I took it for a test ride. Work boots, shorts, t-shirt. Not even a helmet. Pathetic I know. It goes against everything I normally advocate.

The bike rides nice, and no leaks so far. I even rode to work today.

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STT "A" 130
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post #6 of 15 (permalink) Old 05-05-2010, 09:28 AM

 
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glad to hear it man!

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post #7 of 15 (permalink) Old 05-05-2010, 10:45 AM Thread Starter
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That's the first time I've done forks on a Harley. I honestly think the hardest part of the job was just the interference removal/installation. The Electra Glide just has way too much shit in the way. Not to mention all of the chrome crap that's extra.

Now I know why the dealerships hate the "accessory bikes". Maybe I should go in and apologize for the work they did years ago. Wait, they got about $80/hr for their labor. No donuts for them.

Midwest Track Day CR #130
NESBA 130-Control Rider (Former Midwest Region)
STT "A" 130
Track: 2006 GSXR-750
Street: 2011 H-D Ultra Limited (Road Sofa)

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post #8 of 15 (permalink) Old 05-05-2010, 01:46 PM

 
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ha ha ha ha ya i know what you are talking about, that is why when they find out we charge 55 an hour on harleys my wait list is out 2 weeks right now

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post #9 of 15 (permalink) Old 05-05-2010, 02:11 PM
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sell that bitch and get a new track bike Jim

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post #10 of 15 (permalink) Old 05-05-2010, 03:03 PM Thread Starter
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And then what am I supposed to ride on the street?

Hell, it's fixed now. I'll be happy until it breaks again, and then I'll make another thread bitchin about it.

Midwest Track Day CR #130
NESBA 130-Control Rider (Former Midwest Region)
STT "A" 130
Track: 2006 GSXR-750
Street: 2011 H-D Ultra Limited (Road Sofa)

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post #11 of 15 (permalink) Old 05-05-2010, 08:14 PM Thread Starter
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Final Update...

kay, just a few pics of why Harley touring bikes are a pain in the ass to work on. The first post shows the amount of crap that's removed to get to this point.

Pic-1: This is where the leak was on the left fork. The cap is loose so you can see the joint. This is UNDER the upper triple tree, and the cap bolt is though that. Now, I'll show you how you get to that point.

Pic-2: The cap bolts are under the handlebars below the corners of the radio opening.

Pic-3: Looking from the front of the bike. This is a 1-3/8" head, and NO, a socket will not fit between the handlebar and the nut. Thanks again Harley :

Pic-4: My $28 "special tool" from Farm/Fleet. No pair of channel locks I own will fit this bolt without screwing it up.

Pic-5: The cap bolt is finally out. Now you can see the neck of the fork cap through the upper triple tree.
Attached Images
File Type: jpg HD-Forks2010 012.jpg (68.1 KB, 8 views)
File Type: jpg HD-Forks2010 007.jpg (82.9 KB, 8 views)
File Type: jpg HD-Forks2010 008.jpg (57.6 KB, 8 views)
File Type: jpg HD-Forks2010 009.jpg (66.6 KB, 8 views)
File Type: jpg HD-Forks2010 010.jpg (57.8 KB, 9 views)

Midwest Track Day CR #130
NESBA 130-Control Rider (Former Midwest Region)
STT "A" 130
Track: 2006 GSXR-750
Street: 2011 H-D Ultra Limited (Road Sofa)

www.MidwestTrackDay.com / www.MidwestTrackDay.motorsportreg.com / www.facebook.com/midwesttrackday

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post #12 of 15 (permalink) Old 05-05-2010, 08:19 PM Thread Starter
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The End!

Last three pics. The forks disassembled and ready for cleaning, and then one of the Grandson. Austin was having fun with my tools, and helping work on stuff in the garage. Suprisingly, I still had 100% accountability on my tools when it was all over.

The last one is just the bike sitting outside of work this afternoon. I should have gotten a better side shot with the sun, but oh well. This is probably the cleanest it will be all year since I'll be riding rain/shine once it warms up a bit.

Thanks for your patience! If you were bored, then you should have clicked on a different thread. :neerner:
Attached Images
File Type: jpg HD-Forks2010 013.jpg (68.5 KB, 9 views)
File Type: jpg HD-Forks2010 011.jpg (63.8 KB, 10 views)
File Type: jpg IMG00693.jpg (102.7 KB, 8 views)

Midwest Track Day CR #130
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STT "A" 130
Track: 2006 GSXR-750
Street: 2011 H-D Ultra Limited (Road Sofa)

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post #13 of 15 (permalink) Old 05-06-2010, 06:51 AM
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Get that boy some shoes!!

Glad everything got squared away.

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post #14 of 15 (permalink) Old 05-06-2010, 07:01 AM Thread Starter
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Quote:
Originally Posted by scout67 View Post
Get that boy some shoes!!
Papa - where's your shoes Austin?
Austin - "Grandma said..."
Papa - watch where you step. You should have shoes on. (Gave up way to easy)

Have you ever argued with 4 year old? Besides, she was the one giving him a bath, so she has to clean his feet.

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STT "A" 130
Track: 2006 GSXR-750
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post #15 of 15 (permalink) Old 05-06-2010, 07:30 AM
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Quote:
Originally Posted by stkr View Post
Papa - where's your shoes Austin?
Austin - "Grandma said..."
Papa - watch where you step. You should have shoes on. (Gave up way to easy)

Have you ever argued with 4 year old? Besides, she was the one giving him a bath, so she has to clean his feet.
as the years progress their arguing skills get better, or maybe my patience wears thinner, and just response, fine.

Ken.


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