Harley Davidson Sportster 39 mm Front Fork Removal, Disassembly, and Rebuild

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The front forks were leaking on the 1990 Sportster, enough that there was a puddle of fork oil on the lift. In this video I walk through removing, disassembling, and rebuilding the 39mm front forks on my Harley Davidson Sportster. To rebuild the forks the fork seals, dust covers, fork seal retaining clips, o-rings, and damper bolts will be replaced.
I am rebuilding these forks due to them leaking past the seals (likely due to them not being installed correctly in the first place - missing retaining clips on the fork seals) but this same process would be used if you were replacing the fork tubes (adding longer tubes for example).
Man it was hot in the garage. The process for removing, disassembling, and rebuilding the front forks is not too difficult, but I was sweating like you wouldn't believe. Can't wait till this heat breaks.
Pinch bolts are tightened to 30 ft/lbs. Added 10.2 fluid ounces of fork oil to each rebuilt fork.
Motion Pro 39mm Fork Seal Driver: amzn.to/3sy4mkV (Affiliate Link)
39mm Fork Seal Kit: j-and-p-cycles.pxf.io/x92emy (Affiliate Link)
Fork Oil: amzn.to/3gg1J2f (Affiliate Link)
1986-2003 Sportster Repair Manual: amzn.to/3j4tnAX (Affiliate Link)
#Sportster
#forkseals
#rebuild
#HarleyDavidson
T-Shirt from Maui Brewing Company: mauibrewingco.com/
This is the second video I have done with multiple segments and then edited them to stitch them together. Not going to win any awards but I think I did a bit better on this one. I'll learn more as I go.
Visit www.sportsterproject.com/ for more...
Build. Tinker. Ride.

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Опубликовано:

24 авг 2021

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Комментарии : 40

@rickdee67 3 месяца назад

Break the top cap loose and knock the dust cover loose before removing the fork from the triple trees. Good video.

@BabySteev 2 года назад

Hey thanks for taking the time on this. Gave me confidence to get at’er.

@pastorbobncc365 9 месяцев назад

Great teaching my friend have a blessed week

@nightmaremike1092 7 месяцев назад

Bro seriously thank you so much this has to be the BEST video hands down more simple then this it doesn’t get cant wait to fix my leak 👊🏻

@SUPPORTYOURSELF 2 года назад

Great video, thanks for the help!

@kd1542 2 года назад

Nice video. I would have also replaced the bushings while you had the forks apart. I don't understand why you didn't fill the forks with fork oil before installing the caps but no big deal. I usually loosen the caps a little before removing the fork tube from the clamps.

@aimen_a 2 года назад

Thank you for the content, very clear

@SportsterProject 2 года назад

Thank you. Glad it was useful.

@churchtech9681 5 месяцев назад

Thanks so much for posting this video.

@randallissimo 2 года назад

Good instruction. Thank you.

@LuisHernandez-fo3pv Год назад

Helpful video but i think you should always start putting any plug by hand first to avoid cross threading. It would help showing that and explaining it so someone else doesnt ruin the bottom fork

@viergarcia 2 года назад

Exactly the vid I needed.

@lexustech48 2 года назад

Great video sir, earned you a sub! Hopefully picking up a nice little 2007 XL50 tomorrow! Not sure if I want to Club style the bike yet, but I definitely want to convert to a dual front disc setup! Your video should help make that easy. Thanks again!

@joerodriguez9752 Год назад

Very helpful brother ty I just seen mine leaking

@vikerbikeruk 2 года назад

nice video sir..well done I was not sure were tyhe small spring went lol

@willcountypowersports6338 Год назад

Curious on what that hose is coming out of your cam cover? Is that a breather mod running to their?

@garageassembled4701 11 месяцев назад

Very helpful

@veronicastewart1959 Год назад

Glad I found your video, I have a 2008 Sportster 1200 and my dust caps have rusted I know I need to do what you did with mine. I wanted to know in mine has the same size bolt 39mm . ( nut.) Thanks for sharing your video I believe I can do mine. I do have a question, what size pvc pipe could I use? Thanks again from Mobile, Alabama

@supaman396 Год назад

Thank you

@g-loctv6114 10 месяцев назад

Do you have to wait until the forks are back on the bike before you add the oil? Or can you add the oil before installing the forks back?

@kennethrutt7986 11 месяцев назад

Wish mine was going as well...my fork caps are not comming off, even with a 3 ft helper bar.....I think I am to the point of using head...or cutting the bolt head for smaller socket, as the edges of the bolts gave out and my 1 3/8 no longer works....might try a 34mm before cutting...but dang, you all make it look easy.

@andawayigorollinlikeadonut1986 11 месяцев назад

Spay with pb blaster first and a 35mm socket with braker bar put some tape over fork caps and turn to the left they will come off.

@kennethrutt7986 11 месяцев назад

@@andawayigorollinlikeadonut1986 Thanks for the suggestion, finally got them off, looks like the previous owner had put pipe dope on the threads.

@Ialicea5840 2 года назад

thx u

@jasonjohnson3577 2 года назад

Great!

@ACoustaDC 2 года назад

Great video. I thought a 90 sporty would be belt driven... did you convert that to chain drive?

@SportsterProject 2 года назад

Yep I converted it to a chain drive.

@owenwilson7138 Год назад

if you're refilling the forks from "dry" isnt 11.6 oz of fork oil?

@nealraudabaugh7922 2 года назад

@sportster project great video man. Don't you have to drive the upper bushing into the slider tube until its seated and then drive the seal on? Maybe to not damage the seal by using it as a bushing driver

@SportsterProject 2 года назад

Neal, Thanks for the feedback. I guess that would not be a terrible idea if needed, but I have never had the upper bushing and spacer not just fall into place. Not sure you should need to drive it in, at least I can't think of anytime I have ever had to. There is a spacer that sits between the top bushing and seal to keep the seal from hitting the bushing. Probably worth checking to make sure it is seated before hammering the seal home.