Straightening Fork Tubes

Straightening fork tubes requires several special tools including a hydraulic or arbor press, dial indicator and straightening blocks. If facilities are not available locally for straightening fork tubes, they may be returned to the factory through any authorized Harley-Davidson dealer.

Figure 2F-26. Pressing High Point

Figure 2F-28. Straightening Fork Stem and Bracket Assembly

Figure 2F-27. Pressing Fork Tube Round to the factory through any authorized Barley-Davidson dealer. Do not attempt to repair fork stem and bracket assemblies that are badly bent or broken. These bracket assemblies should be scrapped.

Insert two steel gauging bars in the fork bracket and secure in place with two bracket pinch bolts as shown in Fig. 2F-28.

Sometimes the steel bars cannot be inserted into the bracket because the holes are distorted. In this case, press the bars into position using an arbor press. Then, press on the forward edge of bracket to correct "bow shaped" distortion (3) as shown in Fig. 2F-29. Repeat pressing operation until bar is loose in bracket. Secure in place with two pinch bolts.

A bracket assembly is usually out of alignment from a horizontal center line (1) with both legs bent or just one leg bent. (See Fig. 2F-29.)

If both legs are twisted, place bracket assembly in position on arbor press as shown in Fig. 2F-28. Place two straightening blocks under low legs (A and B). With press block (Z) placed straight across bracket assembly, press until legs (C and D) are forced down and into alignment with legs (A and B).

If one leg is bent, place bracket assembly on three straightening blocks, two blocks under straight leg and one block under the low leg. Place press block diagonally across bracket assembly to high leg and press until high leg is forced down and into alignment with the other three legs.

Figure 2F-28. Straightening Fork Stem and Bracket Assembly

Place the fork stem and bracket assembly on the four straightening blocks located on the surface plate, (Fig. 2F-30). If the legs rest squarely on straightening blocks, the bracket assembly is correctly trued.

Figure 2F-29. Correcting Bracket Bow

If bracket is not true, press again, checking alignment after each operation.

Use a square and check to see if bracket assembly is bent or distorted (to either side) as shown in Fig. 2F-31. If so, place in vise and straighten, using Bending Bar, Part No. 96806-40, as shown in Fig. 2F-31.

Check to see if the fork stem is straight, [true on a vertical centerline (2, Fig. 2F-29)] by using a fork upper bracket as a gauge (Fig. 2F-32). If not, place in vise and use Bending Bar to bring into position.

with engine oil. Fork bushing driver and guide (2, Fig. 2F-33) is used to install fork slider bushings. Insert the bushing guide into the fork slider oil seal counterbore and insert the new lower fork slider bushing into the guide. The fork bushing driver has two grooves cut around its outside diameter which are used as depth gauges when driving in the bushings. The groove nearest the top of the driver is the depth gauge for the lower bushing, and the lower groove is the depth gauge for the upper bushing. The lower bushing is driven into the fork slider to the point where the upper groove on the bushing driver aligns with the top edge of the bushing guide.

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