How much trouble is it to change the lower fork tubes? Any special tools, or tricks I need to know about?

Jay

 

Supposedly you need a fork seal driver, but you can use a piece of pvc piping...

 

+1 to that...nice & simple & cheap

 

I can speak from experience. Just did that last month.

It's not that hard.

Necessary tools:

Bike jack
35mm 6pt socket; fork cap removal to replace fork oil.
2 qts fork oil - your choice of weight. HD SE fork oil is 5wt. Some people go to 10w.
12mm allen socket. (autozone has one. it's about 4-5" long and fits perfect on the brake side).
12mm allen is for drain plugs located at the bottom of the lower. "disconnects" lower from damper rod.
12mm 12pt socket to pull the caliper off the lower
A 2" diameter x 2' piece of sched 40 pvc to act as fork seal driver works perfect. Don't buy a cheap piece of pvc. It'll shatter.
SAE allen wrench set; handlebar removal to gain access to fork caps; fender removal
SAE socket wrench set or open end wrenches work too.
Torx bit for fork pinch bolts; don't remember the size.

I found nothing in the service manual that enabled me to do it any better than just diving in and doing it.

If you search my threads started, you can find a detailed write-up of lower swap.

 

Ok guys thanks I am thinking about giving this a try.

Jay

 

if you need tech support, you can give me a call. I do it with computers, might as well do it with harley davidson chrome lowers too.

Also forgot...

5mm allen wrench for two axle clamp bolts on right side fork (non-brake side).

 

Ok my friend that sounds good.

Jay

 

You can polish up the stock tubes while on the bike, just need a bunch of wet and dry sandpaper and elbow grease, comes up very nice for a few hours work, and maybe $20 in papar and polish

 

You gotta remove the bars to swap the lowers out?

 

Thats what I did. Used the trees as a vise. Only time you need to pull the forks from the trees is to seat the fork seal. Other than that, everything can be done with them locked in the trees. Unless of course you get the fork tube tool...