Replace damaged front fork lock on a 1996 harley davidson FXDS-CONV.
Ok, this is how you replace the lock on the front end.
1.Loosen upper triple tree clamp pinch bolts. Remove upper triple clamp and handlebars.
2.Loosen fork stem bolt and let fork stem drop down approx. 5 inches.
Note: On the left side of the steering stem there is a "half moon" indentation that has been machined into the steering stem for the lock. Let steering stem drop until this indentation is in full view.
3. Use a scribe and remove lead plug. (there is a flat looking place below the key lock. The lead plug is underneath this and it hides a set screw. Dig the lead plug out to get to the set screw)
4.Unscrew the set screw
5.Insert key in lock and turn partially.
6.Wiggle lock and pull until enough of the lock comes out to get a grip with pliers or other suitable tool.
7.Rotate steering stem slightly, while pulling on lock until lock is removed.
There is an internal boss in the left side of the steering head opposite the external boss. The end of the lock fits into this internal boss.
There is a hole in the bottom of the lock into which the set screw fits. This hole must be at the bottom when the lock is installed.
When the lock is correctly installed, a forward-facing flat on the lock will fit against a flat inside the external lock boss and the face of the lock will be flush with the face of the external boss.
1.Steering stem should be in above position. See steps 1 and 2 above.
2.Grease the end of the lock (the part that goes into the internal boss) and slide lock into external boss.
Note: Steering stem must be in locked fork position.
3. Move steering stem into locked fork postition. Rotate steering stem sligtly, while fully installing lock.
4.use Loctite 242 (medium strength blue) and install set screw
5.Use key in the lock and tighen set scrw until lock begins to bind; then back set screw out 1/2 turn.
6.Pound in lead plug (or use a good quality sealant)
7. Install fork stem, upper triple clamp and handlebars.
Right out of the book. Hope it helps. Good Luck.
Nov 13, 2009 |
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