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Sportster Motorcycle Suspension, Frame, Forks, Handlebars, Fuel Tank, Oil Tank, Fenders Discuss Sportster Motorcycle Suspension, Frame, Forks, Handlebars, Fuel Tank, Oil Tank, Fenders problems, advice, and/or how tos.

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  #1  
Old 6th August 2022
edharley48's Avatar
edharley48 edharley48 is offline
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Default 2021 Harley sportster 48 front fork cover and gaiter install HELP!

Hello! I'm new here. I posted this same question on HDforums but didn't get much response. Hopefully someone can help me here!

I have some questions about installing front fork cover and gaiters.

A bit about myself. I ride a 2021 sportster 48. I bought the service manual and a bunch of tools and did some DIY install on my bike, such as exhaust, Barnett extra plate kit for the clutch, changed cam cover (including finding TDC) and lots of other things ha ha. My point is, I have confidence in installing parts myself if there's good videos on youtube. However, I haven't seen a good video for removing and installing front forks. I hope someone here can help me!

Questions:
1) What's the size of the 12 point socket for removing the brake calliper?
2) What's the socket size of the large front axle nut on the left side? The biggest socket I have is 7/8 (for use on a 3/8 socket wrench) and it's too small.
3) I only have a 1/4 and 3/8 size socket wrenches and a 1/4 and 3/8 size torque wrench. Can I remove this large axle nut with a 3/8 socket wrench? Will I need to buy a 3/8 size breaker bar to remove the large axle nut? Or do I need to buy a 1/2 socket wrench/breaker bar to remove and install this large axle nut?
4) I am worried about the alignment of the wheel during re-installing the wheel (if the wheel is pointing straight or not). Am I correct to say that the lower portion of the fork can rotate, so when the axle goes through the forks and the wheel, the wheel will be pointing straight?
5) On the 48, there are 2 pinch bolts at the lower bracket of the triple tree. I am confused about the instructions in the service manual on installing these 2 pinch bolts. Attached is the picture of the instructions. Does this mean I have to tighten these 2 bolts 3 times?
https://ibb.co/T843Z04

6) Last question. Is it a good idea to apply medium strength blue loctite on all pinch bolts of the fork, brake caliper bolts, and axle nut?

Is there any other tips or other things I should know when tackling this install?

Thanks for your help!
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  #2  
Old 7th August 2022
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IXL2Relax IXL2Relax is offline
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Quote:
Originally Posted by edharley48 View Post
I ride a 2021 sportster 48.

Here's the XLForum Sportsterpedia section on the Front Forks:
http://sportsterpedia.com/doku.php/techtalk:evo:susp01

Here's the XLForum Sportsterpedia section on the axles/wheels/tires:
http://sportsterpedia.com/doku.php/t...k:evo:wheels01

Read the first section about installing wheels/bearings - The axle clamps all the parts to the left lower leg, then the pinch bolt on the right lower leg clamps the axle to that right lower leg.

Alignment should be self centering unless you change parts from OEM. Be sure to keep track of the sequence of parts as you remove the axle.

If you change parts, then you need to make sure you use the right spacers to align the brake rotor with the caliper and that the spacers center the wheel between the forks.

As to the Triple-Tree Pinch Bolts - Tighten the top TT Pinch Bolts to 30-35 ft-lbs.

Then, it does appear they are recommending to tighten the lower two Pinch Bolts 3-times.
Lower TT - Upper Bolt then Lower Bolt
Lower TT - Upper Bolt then Lower Bolt
Lower TT - Upper Bolt then Lower Bolt
Perhaps they had issues with the lower TT coming loose? Each tightening in the series is the same
Torque: 30-35 ft-lbs. It does not indicate an increasing setting, so it would seem you set it, then
go back & forth to confirm that torque value on each bolt.

Typically, Blue Loctite is to prevent vibration from loosening bolts/nuts. You should be able to use it
most everywhere (except high temp areas & oil/liquid soaked areas) - but the torque value may be
slightly affected due to the viscosity of the Loctite.

http://sportsterpedia.com/doku.php/t...01#front_axles
Axle nut - 7813A- 5/8“-18 x 9/16” x 15/16“ head-nut
You should be able to find a 3/8" drive socket.
A short length of pipe over the ratchet can give you extra leverage, if needed.


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Last edited by IXL2Relax; 7th August 2022 at 02:52..
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  #3  
Old 7th August 2022
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Quote:
Originally Posted by IXL2Relax View Post
Here's the XLForum Sportsterpedia section on the Front Forks
Hello IXL2Relax. Thanks for your reply! Now I can go ahead and purchase those sockets and go ahead with the install. cheers
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  #4  
Old 7th August 2022
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Good luck brother, I hope they designed them better than Honda (have to make a tool or be lucky enough to have 100 different extensions and adapters, and it took them all)

Take pictures if you can, with as new a bike as you have it may help alot if people. (Imgbb.com --> upload --> choose file/camera ---> upload before copy switch type to "full BB code" --> paste here and pictures will display in thread (no need for your own img tag that way as they do it for you, just paste and post.

My philosophy for people without machinist dad's is buy cheap until you break it, then get a good one.

Harleys of our Era like 16th's for some reason (maybe bc they were competing with metric and 5/16 is a hair shy of 8mm and 1+1/16 is dead on for some metric size, the 7/16 us like 4 thou off of 11mm so still pretty close)

No idea your specifics, but you can always measure and get close (and they won'tcomplain about returns if you buy a new wrench)


Also, on the video platform note ...... you'll learn to hate them. For real green beginners they're nice but you will quickly find yourself combing the fsm before they finish asking you to "like and subscribe" and there sluggishness getting to the point will drive you crazy. Just a guess, but that's how it is fir many people I know.
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Old 7th August 2022
Andy56 Andy56 is online now
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The caliper bolts are 10mm.
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Old 7th August 2022
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Quote:
Originally Posted by Andy56 View Post
The caliper bolts are 10mm.
Metric? Are they all that way now. Anyway, 10mm are famous for walking away so keep an eye on your socket/combination wrench. There is no proper (within 10 thou) inch equivalent (well there is, obviously l, but it'll be like in 32nds or 64ths or higher) unfortunately.

The good news is you'll need it if you have a car, a bicycle, a toaster, a hamster ..... Basically 10mm bolts and nuts are everywhere (besides ironheads I guess, obviously exaggerating
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My '06 has 10mm, also. (Showa Forks)
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Old 8th August 2022
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Thanks everyone for your help! I got myself the 10mm 12 point socket for the brake calliper. I will post up pics on the install when I have some time to install the parts (Cult-werk fork cover kit)
https://www.cult-werk.com/harley-dav...s-aktuell?c=40
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