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Poor mans fork seal tool for a professional install

Discussion in 'Motorcycle Tech Talk' started by oldman1, Dec 23, 2007.

  1. oldman1

    oldman1 New Member

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    Hello Everyone, Been on vacation then had to deal with the Oklahoma ice storm and no power for 10 days. Anyway power's back on, Harley's safe in the house and have some information to share with those wanting to install the front fork oil seals, professionally, without going to the expense of 60 bucks and upwards for those fork seal tools that you may use only a couple times a year. I had some pitted lower sliders that I wanted to replace on my 2004 Sportster so I picked up an almost new set on ebay for only 50 bucks including shipping. As some might know its easy enough to get everything apart. I left the forks and tree on the bike, I just removed the sliders, then I invested 2 dollars in a roll of duct tape, 49 cents for a 1 foot length of 1 1/2 in. diameter pvc pipe, and 1.79 ea. for two 2 in. hose clamps. Anyway getting to the fork oil seal install, I slid the new seals up the forks along with the new sliders, screwed the bottom 6mm allen screws, then used duct tape and taped about a foot and a half of tape around the fork tube about an inch and a half up from the slider top lip to protect it, then I split the 1 1/2 in. PVC into 2 equal pieces 2 3/4 in long and placed them around the duct tape on the fork tube making sure it was about 3/4 in below the lower portion of the duct tape, then used the 2 2inch clamps to clamp the pvc together. Make sure you have a smooth edge on the lower pvc pipe and that both pieces are even, then push the slider up so the oil seal and pvc meet, then just tape the bottom of the slider with a hard rubber mallet and 3 or 4 taps perfectly sets the oil seal, slider bushing, and spacer seal. Then just re-install the retaining ring, rubber dust seal and dust cover and your all set. No muss, no fuss, the hardest part was putting on the top fork caps because of the spring tension of the fork springs. Anyway save yourself big bucks on overpriced fork seal tools and do it for under 6 or 7 bucks without any headaches. I'm posting some photo's below, hope they show up. Also hope you all have a great Holiday season.

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  2. chucktx

    chucktx Moderator Staff Member

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    welcome back oldman, and glad ya came through the storm ok! great how to, thanks. i wish i had carpet in my shop to work on!!!!!!!:)
  3. oldman1

    oldman1 New Member

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    Thanks chucktx, your welcome. Glad to be of any help to anyone who needs it. Yeah my wife let me park my Harley in the living room, that way I can do all the maintainence throughout the winter, in a warm carpeted house and have her ready for when spring time comes. As for the ice storm, no damage to the house but it knocked all the trees down in my yard and took 3 days to chainsaw them up into large piles. Here's some photo's of the aftermath.

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  4. chucktx

    chucktx Moderator Staff Member

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    wow....it sure was bad, but glad y'all are ok....thanks for the pics.....
  5. ironhorse

    ironhorse Active Member

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    thought that looked like carpet, great pics, bad ice.ain't your avatar from the devils rejects?
  6. oldman1

    oldman1 New Member

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    Thanks ironhorse, yes the avatar's from devil's rejects, good old capt. spaulding.
  7. voodoochild

    voodoochild New Member

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    Damn that ice storm looked bad, glad you made it through Ok.
  8. oldman1

    oldman1 New Member

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    Thanks voodoochild, yeah it was pretty bad and glad its over with, take care.
  9. cowboy

    cowboy Moderator Staff Member

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    Yep that's some good handy work for the front seal's thank's & you did good getting through the ice storm I have a couple of friend's in OK One in Moore & one OK city both got lucky & keep the elc those pic's make me glad I'am down here in SE Tx
  10. oldman1

    oldman1 New Member

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    Thanks cowboy, yeah I wouldn't want to go through that kind of storm again, no electric, freezing, etc. for quite some time if ever again. Anyway here's the finished product on my sportster with the new sliders, oil seals, dust covers installed.

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  11. chucktx

    chucktx Moderator Staff Member

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    nice clean job oldman!!!!! again, thanks for sharing!!:)
  12. oldman1

    oldman1 New Member

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    Thanks chucktx, glad to be of help to anyone.

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