12. The damper rod and associated internal parts were pulled from each fork tube.12. The damper rod and associated internal parts were pulled from each fork tube. 13. All of the internal components were cleaned while each of the bushings and fork parts was visually inspected for wear. Other than the oil seals and fork tubes (and the 2 top bolts used by each stock tube) the stock parts would be reused.13. All of the internal components were cleaned while each of the bushings and fork parts 14. The new CCE fork tubes (top) are 23/4 inches longer than stock. We previously slid new bushings (arrows) over the end of each tube.14. The new CCE fork tubes (top) are 23/4 inches longer than stock. We previously slid ne 15. Reassembly was straightforward and the same as the factory assembly. Here, from left, is the fork tube (with bushing), damper rod, oil lock stop, and slider. Tip: apply grease to the inside of the oil lock stop. This keeps the damper rod seated properly and straight as the assembly is lowered into the slider.15. Reassembly was straightforward and the same as the factory assembly. Here, from left, 16. We lubricated each oil seal with fresh 15-weight PJ1 fork oil. 17. Using a seal driver, a new oil seal was bottomed out in the top of each slider followed by popping in the retaining ring.17. Using a seal driver, a new oil seal was bottomed out in the top of each slider follow 18. The drain screw was tightened with an impact screwdriver and the damper rod bolt was installed as tight as possible to avoid leaks; final torquing of the damper bolt will be done after the fork cap is in place. Remember that spring tension?18. The drain screw was tightened with an impact screwdriver and the damper rod bolt was 19. Harley recommends adding fork oil with the forks fully compressed and without fork springs or spacers. Although the volume of oil is important, since we added extra length to the fork tubes the stock value changed. A more accurate way of determining the amount of fork oil is to measure the distance from the top of the tube to the fork oil level. To use the fork oil tool, we filled the forks, set the distance (4.2 inches for a ’04 RK) from the top on the fork tube, and removed (through suction) the excess fork oil. When all you get is air in the tool, you have the proper level of fork oil.19. Harley recommends adding fork oil with the forks fully compressed and without fork sp 20. Once both forks were filled correctly, the springs and spacers were placed into the fork assembly. The common notion is to place the springs with the tighter windings at the bottom; presumably to reduce unsprung weight as the lighter (less windings per inch) part of the spring is on top. The new fork cap bolt was then muscled into place.20. Once both forks were filled correctly, the springs and spacers were placed into the f 21. We installed the stock rubber bushings and spacers into the TourTrac Tree.21. We installed the stock rubber bushings and spacers into the TourTrac Tree. 22. The TourTrac Tree was secured to the stock fork stem with the stock nut and locking plate but not tightened yet.22. The TourTrac Tree was secured to the stock fork stem with the stock nut and locking p 23. Each complete fork assembly was slid through the bottom triple tree. The rubber damper goes between the triple trees.23. Each complete fork assembly was slid through the bottom triple tree. The rubber dampe 24. Once the fork cap nut was in the proper position the pinch bolt was tightened.24. Once the fork cap nut was in the proper position the pinch bolt was tightened. 25. The ignition switch, risers, and handlebars came next. 26. The fork stem nut was tightened, and then the lower pinch bolts. It’s vital that the endplay of the triple trees/neck stem are adjusted properly to ensure good handling.26. The fork stem nut was tightened, and then the lower pinch bolts. It’s vital that the 27. We reinstalled the stock Road King headlight and nacelle. 28. Finishing the installation we replaced the fender… 29. …followed up with the front wheel and brake calipers before getting the King out on the road.29. …followed up with the front wheel and brake calipers before getting the King out on t Source Custom Cycle Engineering (800) 472-9253 | customcycleengineering.com Mail baggersmag@sorc.com « | 1 | 2 | View Full Article By Toph Bocchiaro Enjoyed this Post? Subscribe to our RSS Feed, or use your favorite social media to recommend us to friends and colleagues!
