Harley Sportster Complete Forks Rebuild !

Stripped, Cleaned, all new consumables and fresh oil too...Forks Done !
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Wiha T-Bar Torque Wrench:-
www.spanner-monkey.co.uk/Wiha...
Wiha Smooth Jaw Wrench Pliers:-
www.spanner-monkey.co.uk/wiha...
Sealey Fork Seal Driver Tool. 35mm - 47mm :-
www.spanner-monkey.co.uk/fork...
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Gedore Red 172 Piece Socket Set:=
www.spanner-monkey.co.uk/Gedo...
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www.spanner-monkey.co.uk/spec...
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[@ProfessionalMonkey]

This is a great freaking video!!!! I am sure I will watch it another 500 times before I tackle my own forks on the chopper. The only problem I know I will have is that both forks leak so I can't measure what I take out, and they are extended, about 45" long, so I don't know how much fork oil to put in them!

[@RC135crewchief]

Thank you so much. I rebuilt my forks with your instructions and the bike has never rode better.

[@mickeym8778]

Best motorcycle forks video on youtube. every possible question answered.

[@seanwilson471]

My wifes ageing Sportster seems to have those progressive springs fitted, im pretty sure they were original as the forks never appear to have been serviced from new. Came with 30k miles the seals went a few years ago and now ive just had to do them again with new stanchions as they had a front end bump. A very slight bend which i believe caused them to leak again. They were always installed small coils to the bottom. It says in the manual to put the tapered end down but no real taper. I might turn them the other way before assembly. I little tip i worked out to seat the dust seal and the chrome cover cap, place the old dust seal over it and use the driver onto that to seat it down. Place the chrome cover on then the old dust seal again and use the driver to tap that down. Cheers

[@Moonfleet41]

Could well be original, Harley make changes to specification constantly, often with no apparent reason..! great to hear you're taking good care of yours. !

[@seanwilson471]

@@Moonfleet41 oh it's unreal reading through the parts manual to get the right model and variations. It's classed as 1200 Sportster low. Wheel bearings can be a nightmare with 1 inch, 3/4" spindles and some are metric. PS Jersey Harley are superb service for parts.

[@daisbestH2B]

Perfect video showing how it's done, THANK YOU !

[@Moonfleet41]

Thanks for your kind words, we're glad to hear you enjoyed the video!

[@mitytoes69]

Good stuff Delboy! Very thorough as always, precise and right down to the point! Thank you mate! Cheers !

[@Moonfleet41]

Most welcome buddy, glad you enjoyed it!

[@mitytoes69]

@@Moonfleet41 Yes sir! I did... good stuff. Only that I am having a hell of a time with the seal right after the washer... made a makeshift driver with pipe and dumbell locks lol... but that damn seal will not go in all the way for the life of me :/ just need a hair to get the clip in... Harley Sportster 2008 1200 xl... dying to get back out on the road! Thanks again! Maybe i should of used the bearing grease... i used silicone bearing spray instead. Scarred of popping seal back out. No worries!! I’ll get it figured out 😎

[@strentin13]

Grazie...fron Italy. Thank!

[@williambowman7618]

my 05 sportster is back on the road! thank you

[@rickrogers2649]

The hits just keep coming in this build. My personal favorite this time was the clear plastic under the seals as you slid them down the tubes. So much respect for your skills and meticulous attention to detail and that goes for the lovely lady behind the camera as well. Many thanks to you both !!! ❤️👍👍

[@Moonfleet41]

Thank you Rick for your kind words, we do work hard to create watchable and enjoyable videos, so we both appreciate that. Have a great week, keep safe, D&Px

[@thevisualshaman]

This guy is giving me the confidence to never go to another motorcycle repair shop and pay ridiculous labor prices. He explains it so well.

[@Moonfleet41]

Thank you.

[@user-ok8qs4gr3k]

Very easy to understand

[@davidhoughton273]

Hello Del, another forking good video. All the best, David.

[@Moonfleet41]

Thanks David,👍 Glad you enjoyed it.

[@kennymacm3031]

Not been on the channel for a while, fantastic. I’m currently stripping my Ducati monster and always find your stuff very helpful

[@garageassembled4701]

This video reminds me of a fine rifleman gunsmith from England!

[@user-zu9kq3iu5r]

Good Day! I've used this as a basis to do maintenance on another motorcycle, thenonly difference was one side of my damper rebound spring fits very snug on one side but when rotated it's very loose, which one would be correct

[@paulharast1958]

Awesome 👌

[@Moonfleet41]

Hi Paul, good to hear from you again, hope life is good, thank you as always for your support!

[@CollinGross-se7cc]

Rarely will I leave a comment on a video. This is such a fantastic “how to” I just had to say, thanks for getting to the facts and being so easy to follow along!

[@Moonfleet41]

Glad you enjoyed it, and thanks for your feedback!

[@jasonshortphd]

Two years ago I never would have attempted rebuilding forks. But because of your channel I have now done two sets. It’s so satisfying! Thanks for doing what you do!

[@Moonfleet41]

Most welcome Sir, we're glad it can help you, after all, that's the reason we started doing it this all those years ago!

[@davidcort2857]

Hi Del, never would i challenge your bike engineering prowess, but my Bandit manual says tighter coils at the bottom, is this something i should try next fork service ????

[@Moonfleet41]

Hi David, if your bike has progressives from the factory and the manual advises tight coils at the bottom, then they will have calculated the fork oil level with that set up, so naturally you must go with that set up... if, on the other hand like with this Sportster, they come with linear springs, then the fork oil is calculated with linear springs, so if you're going to fit progressives, it's best to keep the tight coils out of the oil for the reasons I explained in the video... so you're good to go mate, stick with what you have.

[@gerrypowell2748]

@@Moonfleet41 yes the general guidelines are tighter at the top,I just researched it as I was doing my own Yamaha👌

[@davidcort2857]

@@Moonfleet41 Marvellous Del thanks so much.

[@rafaeljoaquim9101]

Top demais

[@motorhead7407]

Well executed Del.Very enjoyable to watch.cool to see someone representing sth australia on your plate wall too.

[@Moonfleet41]

Thanks mate, it was a gift from some good friends down under, and what awesome numbers to have on your car aye?!

[@motorhead7407]

@@Moonfleet41. yeah very cool.when ya comin down?lol

[@springy-2112]

Tidy job buddy. You know those jobs you've done dozens of times bit still hate ? Well that's forks for me .. I've never had big issues ,always worked fine but I just really find it hard to start the job . I've got good tools and a homemade air gap tool . Always managed to remove the bottom bolt usually with an impact gun Or a subtle blend of psychology and extreme violence ! It's just one of those jobs .. It's nice to watch someone else do it so calmly though . Cheers buddy ! Peas n loaf ✌💚

[@Moonfleet41]

Hey brother, 'psychology and extreme violence'... a great solution for many problems! I know what you mean, forks is one of them jobs aye? But it doesn't take long, the more you do it, the quicker it gets... have a great week Sir, and keep safe, D&Px

[@renzovc]

Another great video brother! When I did mine I followed your previous videos and it was so easy to do ! love the trick of protecting the seal when sliding in the forks ! keep up the great work brother ! stay safe guys cheers from new york!!!!! 🍺🍺🍺🍺

[@Moonfleet41]

Sure thing brother, am glad you liked it, protecting the seal is important with old forks, there are always little nicks and marks in the old stanchions, so it's safer than risking damaging the new seals! Have a great week both of you and keep safe over there, D&Px

[@pearsehall1049]

Great stuff Mr D

[@Moonfleet41]

Thank you Pearse, lovely to hear from you, hope you're both keeping safe and well, we'll see you soon!

[@whiteywhiterson406]

Can you tell me the torque spec on the bottom allen bolt that threads into the dampening rod? You used a torque driver on it. Manual says 22 to 29 i believe. Is that correct?

[@softailfun]

Job well done and they certainly look the part mate. She’ll be a beauty when finished. Hope you’re enjoying the weather down South. Take care both.

[@Moonfleet41]

Hi brother, yes, enjoying some sunshine at last, hope you both are too! Have a great week and keep safe, D&Px

[@Speedytrip]

Simple, clear, to the point. Excellent!

[@tinks43]

Glug glug glug glug glug, how satisfying. Well done both of you 👍🏻😎

[@Moonfleet41]

Hey buddy... thanks for your support as always.. hope you're all keeping well.

[@enduromotorradtouren]

Great work! Loved your trick with protecting the seals when sliding them over. Simple, but effective. Thanks for your channel. Günter from Nürnberg/Germany

[@MintyGusto]

@@23DMOTORSPORTS do I sense some jealousy? You keep commenting on people's comments. Is that in the vain hope they will visit your channel and mistakenly hit the subscribe button? Leave it out

[@LS-uv9gg]

Ahh, another great episode. What a treat to be able to finish the work on repairing my dropped and shattered stupid phone, brew a cuppa, have a toasted bisquit and watch this. Thanks man :)

[@Moonfleet41]

Hey buddy, always good to hear from you, take care and keep safe!

[@ObsessiveCarDetailer]

Im not even going to think about the mounting cost of the project Del but its bloody entertaining👍

[@Moonfleet41]

Thank you kindly Sir, it's nice that you notice that, I am starting to wince a little now at the investment, but it's well worth it, the wheels arrive this week and they'll be absolutely beautiful.

[@TechnMoto]

👍👍

[@scousebikers]

My springs even stock come out at the top alot more and its a struggle to get them back in recon I'm doing something wrong ?

[@MrMikeSteves]

The progressive shock works as the word states. The closely spaced spring rate goes in first. To get progressively suspension rate

[@tubbyglide6859]

@@bikesmith they should be fitted they other way! Look at the manual

[@myz06rocks]

i don't know when i'll have to do my forks again but the reminder of how it all works and goes together is always great. Seems like it's the one thing i can't seem to memorize :) Have a great week!

[@Moonfleet41]

Thank you buddy, yes, sometimes I have to look at the manual just for a re-fresh, as do all mechanics, not matter who they are, nobody can memorise everything... take care and have a great week Sir!

[@garya3056]

This is a great primer for everyone on changing oil in the forks. Very helpful, Del! BTW, I had both of the forks off my Fatboy yesterday just to clean them up a bit. This morning, one of them was gone from the garage. I’m sure you won’t be surprised to hear that I discovered my MIL had taken it to her sleeping bag for the night. Heavens knows what that poor device was subject to overnight. Now of course. I have to figure a way to sterilize it before reassembling the bike. I notice the MIL is smiling a bit today. She still smells the same but there’s also slight whiff of oil in the air when she walks and she doesn’t creak as much. Oh well... Thanks for a great vid 🏍👍🏍

[@Moonfleet41]

Gary, you are a 'sick puppy', I love it! ...I guess a scrub down with the wire brush and caustic soda should see her straight... have a great week Sir, I'm off to get a cloth to wipe the tea off my screen!!

[@garya3056]

@@Moonfleet41 ok I’m on it! This is what I get for taking in wild animals and trying to domesticate them. 😊 Have a great week there, both of you.

[@travisray139]

Have you used a Motion Pro fork oil level tool? I imagine you have- but if not, check it out. Can set the level precisely, and makes a quick clean job of it too. I finally broke down and bought one. Worth it. :)

[@Moonfleet41]

Yes mate, I've seen them, it's on the list with everything else... thanks for the nudge!

[@robertengland9352]

Excellent as per usual

[@CoastlineMx]

What kinda seal driver set are you using I really like the design of them . Also what kinda of spray paint did you choose to used for you triple trees ? Just a note I love your channel cheers!

[@Moonfleet41]

Thanks for the kind words... and Fork Seal Driver for you mate, hope it helps: www.spanner-monkey.co.uk/fork-seal-driver-115817?search=ms016&description=true

[@REKLESSWOLVES1]

Cheers for this video mate, doing my fork oil change this week on my 2000 US Import Sportster, by the way when we chatted on Facebook Messenger last week about the turn signal issue i had, i resolved it, basically all i did was tape over one of the filament contacts on the front light bulb, that stopped the running lights being permanently `ON`, it`s the BLUE wire that`s the constant live so while i`m doing the fork oil change i`ll also trace back the Blue wire to the terminal and remove it completely for a permanent fix, thanks for your advice on that buddy, following this build with great excitement as we have the exact same bike almost, and later this year i`ll be doing the S&S 1200cc conversion on mine so these videos will be invaluable to me, so cheers for that. Love to The Bride

[@Moonfleet41]

Cheers Claypole, really appreciate that buddy, and am glad the wiring hack worked... good news you got the right bike, now we can be 'Sportster buddies' lol... always happy help if we can, you know where we are! D&Px

[@REKLESSWOLVES1]

@@Moonfleet41 cheers bud, not sure if this is your `bag baby` but instead of using tough black simoniz on my fork lowers, i bought some harley vivid black base from a place called `Inspire Paints`, also bought a can of 2K clear that has one of those `pull / twist / pop` ring pulls for the activator hardener, etch primed them, floated 3 coats of black base on and 4 coats of clear and they`ve come up brilliantly, hardened in 48 hours fully so you can wet sand and polish, no need for a booth either, they look so good i`m going to redo the fenders and tank in it, cracking paint mate you should do a video maybe in the future.

[@markgosling9253]

Good to see the project coming on well, is there a different way to do fork seals or do you need the sliding hammer?

[@nickhellen6303]

Have to say that trick with the plastic was a great idea. I’ve never even thought of doing that. However, I’ve bought Veterinarian syringes to fill up my forks - the biggest holds 100mm and provides pinpoint accuracy. No more Pyrex jugs for me. The syringes( obviously different ones) are also great for brake bleeding both in removing fluid from the M/C and in reverse bleeding at the callipers. And for filling BMW final drives. Lovely work.

[@Moonfleet41]

Thank you Nick!

[@jeremynelson8496]

Going out to check if I have those chrome caps today and gonna chuck them if I do. The bike parts are shaping up nicely.

[@innes59]

👍

[@brianwells5258]

Great job.....,loving every update and following along., enjoying this build every step of the way... Oh and I totally "get" what you were saying about the spring orientation and your reasoning behind the way "you" do it...... Made perfect sense to me...... Well done.....,oh and the editing and camera work is Top Class...!! BG.

[@Moonfleet41]

Thanks Brian, it's increasingly pointless to explain things these days on the internet, but now and again, when it's so blatantly obvious, then it's worth it if it can help someone make a decision! And thank you for the your kind words on the editing/camera work, it is much appreciated!

[@brianwells5258]

@@Moonfleet41 100% agree Del... Keep doing what you are doing.......,like I said on a previous upload.,I'm with you every step of the way on this one.......,and I'm not even a Harley guy..!! (I build ZRX's etc...) The principals.,methods and approach applied here translate over to pretty much all bikes "on the table" and the content is keeping me hooked.. Shaping up to be a cracking bike when its done......,but I personally hope that is a long way off as like any good "series"..,each episode makes you wanting More.!! Top class work all round to you and your excellent camera girl...!! BG.

[@institutionalpriceaction]

OIL CAPACITY PER TUBE

[@veeken777]

4 forks sake, they are lovely

[@rsbharley4766]

Excellent video Del & Penny. Job well done mate, very relaxing watching you rebuild your forks LOL. Stop using them smooth jaw pliers, you're making me jealous. I think my pair must be taking the long way round to get here and I wish you would stop costing me money LOL . I also see you got a little mentioned in uk real classic bike mag . the guy watched one of your how to paint with a rattle can videos. Penny and you have a good week. Cheers

[@Moonfleet41]

Hey buddy, sorry to hear your pliers are delayed, but I can say they are definitely worth the wait!... and thanks for the heads up on the classic bike mag, it's not one that I read, but there's bound to be a copy in the local shop, so I'll give it a look! Great to be appreciated... take care and have a great week!

[@rsbharley4766]

@@Moonfleet41 Hey Del, check your email and message on facebook as don't know if the email address was right. Cheers

[@TheGreatestBeyonder]

Question (for anyone really)… but is the ‘air gap’ measured with the fork in the shortest position (fully retracted)?

[@Moonfleet41]

Yes!

[@chrispayne1029]

Great Video great job and a very important job to do right Del 👏👌👍

[@vn800ride]

Fork oil weigt number plase?

[@garethburningham9467]

Cracking job mate...

[@duchman99backup51]

U make it look easy del.....👍👍

[@Almightyrastus]

I'm just here for the oil filling noises...

[@JDnBeastlet]

Gloop gloop gloop

[@Arni0111]

Love those fork rebuilds, this channel taught me how to do forks, both the plastic tube way and with a decent forkseal driver. Did my F800GS 43mm WP forks and what a difference.

[@richardplantagenet8090]

You're early today m8; not that I'm complaining.

[@Moonfleet41]

Thanks mate, finished the editing early, so why not. !

[@JDnBeastlet]

Hey Del and Penny, great video! Del, thanks for the tips on progressive springs and which way goes up. Makes perfect sense to me - more volume of spring displaces more volume of fork oil. They look great!

[@Moonfleet41]

Sure thing buddy, and as I said, you can always suck a little oil out, but you can never know how much, to get it right because you can't measure the oil level with the spring in place, it'll only ever be a guess at best, and fork oil level is important, if not critical for a smooth ride. Thanks for your kind words, we both appreciate it.

[@biga9203]

Seriously i wish you are here in Saudi . man your videos helped me alot with my iron 883 2016 thanks is not enough wish all the best for you and Penny .

[@Moonfleet41]

Thank you for your kind words!

[@tubbyglide6859]

Surely you fitted the coil springs upside down? They came out on your previous video the other way? And in the service manual….

[@LS-uv9gg]

I have no dog in this fight, but I've discovered like "which oil is best", "how to do a proper break-in", etc., etc., for every "they go up" faction, there is a counter faction with the argument for "they go down". For example: The spring manufacturer Hyperpro (which I would assume know what they are doing) says in the instruction manual to install their springs with the tight coils up top, while the (Yamaha FZ6) manual says to put them in the other way 'round. Honestly I don't think it's a show stopper or worth fisticuffs over at the local pub, no matter which choice is made lol. Cheers

[@Moonfleet41]

Neil!: perhaps you missed it Neil!, these are NOT standard manufacturer springs, they are after-market upgrades... so the oil level would be set for that arrangement... hence I leave the tight coils out of the oil, as explained!

[@motorhead7407]

was trying to edit a reply and mucked something up now ya reply gone sorry mate im a little tech challenged.

[@Moonfleet41]

No worries mate, always good to hear from you.

[@MrAndyCarlos]

I can't wait to see the full restoration!

[@loddude5706]

Clear, precise & beautifully shot - nice variable radius curved surface drift from Wiha, they must have had animals like us in mind. Agree re the spring coils too, once compressed, those tight coils become a solid rod of unsprung weight, better to have them above the springing, where they can do their job of damping out the wayward harmonics of linear boing. AND their nervousness can't froth the oil up! (Those chrome slider caps might look good as part of a cake stand : )xx

[@Moonfleet41]

Thank you kindly Sir, we really appreciate that, and as always, love your lyrical excellence. D&Pxx

[@clark7169]

Nice one Del. Great tips as always. Never come across that type of drift before but it seemed to work a treat. Do you find it easier to get the main caps on while the forks are off the bike? It was like wrestling a gorilla last time I did it. Poor Penny's Pirex. Just hope you don't get served a strawberry tart for tea, it could be a bit oily around the edges. 😜🇸🇪🇬🇧👍🏻

[@Moonfleet41]

@@clark7169 Hey Paul, she hasn't noticed I've nicked the jug yet! And you're right, the strawberry tart would be extra tangy with a bit of 10W mixed in!! With the caps, they're the same whether the forks are on, or off, the bike... it makes no difference, but what makes a difference though is if they've become loaded up with crud... if they're completely clean like these were, they ping off with a few taps in the notch area, but on the Dyna, mine were thick with crud, I had to tap all round them, a bit at a time, and dented them in a couple of places as they are very thin metal... as you can see , they're only for looks so relegated these to the 'Wall of Pointless Parts' for posterity!

[@clark7169]

@@Moonfleet41 10W finger licking good lol. Apologies Del i meant the top fork bolts or caps as I call them. Very difficult to start the thread engagement while trying to compress the spring at the same time. I was huffing and puffing like an old buffalo. You made it look easy. Maybe I need to get a new gym membership.😂👍🏻👍🏻👍🏻🇸🇪🇬🇧

[@Goldwing1500rider]

Makes whole lotta sense which way springs should go… I turned mine around to hold fluids better ( tight end up) , my thinking before, prevent air bubbles as mentioned when bounce. Hot summer heat 100 degrees creates expansion ( some don’t agree) when hard riding. Great lessons here… great advice and video…

[@Moonfleet41]

Thank you for your kind words buddy.

[@n22pdf]

Top job Del very nice mate

[@raydouglas5896]

Another great instalment of this build. Loving it.

[@coloradokid1346]

Great video Del. Love your attention to detail about the spring on which end to put in first. Great tip.

[@Moonfleet41]

Thanks buddy👍, like the saying goes, "that's just my take on it and why i do it that way".. im sure others do differently. !

[@richardwhittle2302]

Great guide to Fork Assemmbly Del - you made that look easy 👍

[@Moonfleet41]

Thanks Richard 👍

[@leighmarshman3522]

That reminds me I need to do my fork seals hope your both well aye🤘

[@FREE_PUREBLOOD333]

Nicely done..no messing about n all back together bang on. "Next!!!'

[@andyjrichie6709]

Great video Del and critical advice, another mint job sir

[@Moonfleet41]

Thanks Andy👍, good to hear form you mate, hope you're both well.

[@AshleyJohnson-j2hno]

Nice job 👍

[@elemz_9283]

first time i see so many respect to a forks, well done. Good job.

[@KevinJones-cr6go]

Be great if he said what sized tools

[@Ghost-zz2lv]

Best of best ,Delboy.. Merci

[@andrew1977au]

Job well done, they came up looking tops. I've had great results from running an even thicker hydraulic oil than the screaming eagle fork oil when using those springs, it matches the spring rate better. Give it a try

[@vonryansexpress]

Excellent - super video as always . .

[@andriesvisser1470]

Is awesome you keep teaching us new ways to do things

[@MintyGusto]

Spot on! They look fantastic. Great attention to detail too. Love the tools you used to get the internals in place too

[@paullavallee1631]

Tidy work

[@andyhutch8262]

Hope wife dosnt use Pyrex jug when she is cooking, make life interesting if she did!!

[@nicholasbishop3300]

It's always a pleasure to watch your quality workmanship in action Del Nick Australia

[@Moonfleet41]

Thank you Nick, have a great week there mate!