Houston we have a problem!

xena · #1 13th March 2005

I'm putting things back together after installing the fork lowering kit. First, there's no way on this earth that Xena has enough strength to get those damn fork caps back on, but I'm hoping I can get one of my burly guy friends to help with that tomorrrow.
For now, I'm putting the front wheel back on but when I took it off, the spacers and washers just fell to the ground and I don't know how they all go. I do have a service manual, but it's not showing me an exploded view of how these washers and spacers go back on. Can someone help?

Darhawk · #2 13th March 2005

Hi Xena,

I'm looking at a 2005 parts manual, XL883, XL883C, XL883L, XL883R and it shows the following, working from the outside inward:

nut
lockwasher
thin washer
wide bearing spacer

it does not show the thicker spacer that you have at the edge of the table. The other items you have laid out on the table are in correct order. The thicker washer or spacer may go against the bearing, but neither the service manual nor the parts manual show it.

IronMick · #3 13th March 2005

To install the fork cap bolts the front wheel must be off the ground. It helps greatly to have a 1,3/8" socket on a 1/2" [or 3/4"] drive ratchet.

I start on one side of the bike slightly toward the back, and while pressing down hard, walk around the front of the bike to the other side toward the back. Usually one thread will catch and that is enough to get started. I wouldn't trust it tho until at least 2 or 3 threads are started.

You can do it Xena!

RedRider · #4 13th March 2005

Hang in there kiddo!

Take yer time threading the caps....an ounce of prevention is worth a pound of cure...

I'm sure someone will have the correct order for the spacers & get it posted.

You efforts will be worth it in the end... Let us know how it works out.

cantolina · #5 13th March 2005

I probably should stop doing this, but.....

My clymer goes to 2003...

Hope it helps...

I saw you had the cast wheel...

BTW, you may have to right-click it and save it...(if it won't open in your browser..)

xena · #6 13th March 2005

Thanks for that Cantolina. I still can't figure out which side the fatter spacer goes on. The exploded view shows #5 as spacers on either side, but I've got two, one fat one, and one thin one.
Far as the fork caps, I will need to get a guy to help. I can't even push the fork caps down enough to start the threads. Not enough muscle in this old girl.

Gyahmers · #7 13th March 2005

Xena, going from left to right you have the correct order for the spacers in your photo.

Axle, left fork, thin spacer, wheel, larger spacer, right fork, washer, lock washer, nut.

xena · #8 13th March 2005

Quote:

Originally Posted by Gyahmers

Xena, going from left to right you have the correct order for the spacers in your photo.

Axle, left fork, thin spacer, wheel, larger spacer, right fork, washer, lock washer, nut.

Thanks very much Gyahmers..uh oh though. So, the fork marked L goes on the brake pedal side of the bike? Shittttt, for some stupid reason I thought left was as you were sitting on the bike.

edit: I put them on correct. lol. Actually can't put them back on wrong now that I look at it.

flathead45 · #9 13th March 2005

the left side is the brake side , for a real sportster

j/k xena , good luck

xena · #10 13th March 2005

Lol. All you guys disappeared on me. Well I've got it all back together except the fork caps so I wrapped plastic over the forks so no dirt would get in until I can find a way to get the caps on. Oh yeah, Mick, the wheel is off the ground. The bike is on a lift.

Gyahmers, that thinner wheel spacer is slightly concave on one side. The HD service manual doesn't mention this, but I assumed that the flatter side would go against the wheel so that's the way I put it on. I've got a little bit of swooshing sound when I spin the wheel, so I have to redo the wheel using the 7/16" drill bit method mentioned in my manual. I couldn't find that size drill bit last night. Also, that fatter spacer has some notched "v" markings on it. Manual didn't mention this either, so I guessed and positioned the spacer with the notches against the wheel.

Lastly, I don't have a 1 3/8 socket. All I've got is a 1 3/8 wrench. Gonna borrow a socket so I'll give it another go in a couple of days when my arms stop hurting. lol. I know this job is no big deal to you guys, but my arms are killing me from trying to wrestle down those caps....which incidentally, I think I found out why. I cut the pvc spacers too long because I measured from the top of the fork opening to the bottom of the fork cap when I should have measured from the top of the opening to the o'ring on the fork cap to allow the distance for the threads on the cap. I think if I cut them down accordingly then I should be able to get the caps on. We'll see. At least I didn't cut them too short.
Thanks again guys for the help and support. If it weren't for this forum I am positive that I would not have attempted this myself.