Harley Davidson Sportster 39 mm Front Fork Removal, Disassembly, and Rebuild

The front forks were leaking on the 1990 Sportster, enough that there was a puddle of fork oil on the lift. In this video I walk through removing, disassembling, and rebuilding the 39mm front forks on my Harley Davidson Sportster. To rebuild the forks the fork seals, dust covers, fork seal retaining clips, o-rings, and damper bolts will be replaced.

I am rebuilding these forks due to them leaking past the seals (likely due to them not being installed correctly in the first place - missing retaining clips on the fork seals) but this same process would be used if you were replacing the fork tubes (adding longer tubes for example).

Man it was hot in the garage. The process for removing, disassembling, and rebuilding the front forks is not too difficult, but I was sweating like you wouldn't believe. Can't wait till this heat breaks.

Pinch bolts are tightened to 30 ft/lbs. Added 10.2 fluid ounces of fork oil to each rebuilt fork.

Motion Pro 39mm Fork Seal Driver: https://amzn.to/3sy4mkV (Affiliate Link)

39mm Fork Seal Kit: https://j-and-p-cycles.pxf.io/x92emy (Affiliate Link)

Fork Oil: https://amzn.to/3gg1J2f (Affiliate Link)

1986-2003 Sportster Repair Manual: https://amzn.to/3j4tnAX (Affiliate Link)

#Sportster
#forkseals
#rebuild
#HarleyDavidson

T-Shirt from Maui Brewing Company: https://mauibrewingco.com/

This is the second video I have done with multiple segments and then edited them to stitch them together. Not going to win any awards but I think I did a bit better on this one. I'll learn more as I go.

Visit http://www.sportsterproject.com/ for more...

Build. Tinker. Ride.