Hey gang. Rebuilding the front forks on a 2008 Ultra Classic. Once I got the fork disassembled I noticed that it was NOT assembled in the same way as the Clymer manual pictures. I have included the Clymer diagram along with a photo of how my forks came apart.

My main concern is that the damper valve (item 7 in diagram) was underneath the spring (item 8 in diagram). The fork cap bolt (item 1 in diagram) was screwed down directly onto the spring. The Clymer manual obviously shows the opposite with the dampener valve being between the fork cap bolt and the spring.

My question is, did whoever assemble these forks last make a mistake or is something else going on here that escapes me?

How my fork came apart. Notice the dampener valve at the bottom side of the spring.

Clymer manual

 

I don’t see the pics you are referring to, so with that said it sounds like the Clymer manual is incorrect. The dampener Should be under the spring like it was when disassembled.

 

 

Clymer Wrong ... You Right

Btw, #7 would NEVER work correctly in Clymer's position


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Thanks for the help folks!

Cheers!

 

Now you know why so many people say the only manual to use is the one that costs an arm and a leg...

 

With all things considered, in the last 3 weeks I have replaced the pistons, cylinders, heads, stereo, half of the suspension, replaced every seal and bearing along the way and swapped out the entire transmission using the Clymer manual. During this front fork rebuild was the only time I found an error in the book (and I've gone through almost all of it by now). Luckily I have some mechanical experience and decent instincts which told me something was wrong. Between these forums, Google & You-Tube a person doesn't even need a manual these days however, a manual is nice since it puts all of the information in one place. With that said, there is always somebody who has done it before and has created a how to video, a tutorial or who hangs out in forums answering questions. The internet age is a wonderful thing - IF you have the time to research stuff.

Not to sound overly defensive because I'm not trying to be but frankly I am very content with my Clymer manual. It has done me extremely well and I would recommend it to anybody on a budget. I suspect many people who praise the HD manual while looking down their noses at others are the same types of people who look down on Honda's, Victory's or even Indians at the stop light simply because they don't have an HD badge stuck to the side of them. Being brand specific isn't my cup of tea - good, bad or otherwise.

 

It clearly has not done you extremely well, it had the fork assembly sequence wrong...

Luckily you were able to ask on a forum, and get answers from people who don`t use the Clymer manual for anything other than a doorstop.

On second thought, I highly suggest you continue to use the Clymer manual.

Bye

 

Oh! The sensitive type. Sorry Cupcake.

 

I`ll skip the manual debate and say that`s a lot of work for 3 weeks. Congrats on your project.