DIY Network

Fork Restoration From "Classic Rides" episode DCLR-105

Figure A

One of the great things about restoring a vintage motorcycle is that you sometimes get the opportunity to improve on the original design. In this segment host Kevin Tetz is joined by resident Harley-Davidson expert mechanic Bill "Dunk" Dunkelberger, who shares his secret about fork (figure A) restoration.

The '65 Electra Glide actually didn't have a method of putting fork oil in from the top. They had drain plugs but no way to put the oil in, and on the project bike the drains are "really" sealed -- well.

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	Figure B
	Figure C
	Figure D
	Figure E
	Figure F

Dunk's Secret Fork Restoration Revealed

• First, he located some caps that already have holes drilled into them.

• Next, he took the fork off the bike using a large wrench to loosen the top fork nut.

  Tip: Spray lubricant into the forks to loosen things up.

• Loosen the middle retaining nut (figure B). Dunk had to use a mallet to tap the cap and force the fork fitting down. Unscrew the cap until the fitting is almost out.

  Note: Before going too much farther, tighten the fork bracket, which holds the two forks and the stem from the bike frame, down because you won't have any hold on the cap otherwise.

• Use the triple tree (figure C) to hold the fork force so you can knock the cap loose. You don't want to knock the triple trees out of alignment.

  Note: When you're working on an old bike, according to Dunk, it's typical to have trouble getting the fork out. And be careful because it's under spring tension. And it's easy to get hurt if the cap flies off when you unscrew it.

• With the fork standing on a wood block (figure D), hold the top cap with a wrench and turn the fork to release the spring inside.

• Remove the spring retaining cap. (On the project bike, the retaining cap and spring are in good shape and won't have to be replaced.)

• Pour the old oil out if there is any -- there wasn't with the project bike, which is why there wasn't an oil leak.

  Note: The forks for the project bike take approximately 6-1/2 ounces of "E" type fork oil, which comes in a sealed container and should be used fresh. Be sure to check the manual for the oil type and fill level of your bike.

• Put the fresh fork oil in.

• Pump the fork to distribute the thick, fresh oil, and then do the exact opposite (reverse) of what you did before to put the forks back together. Due to the spring's tension, you may need help in reattaching the cap as Kevin assisted Dunk for the project bike.

• The serviced fork is then installed back on the bike by slipping it through the fork slider cover and up into the tree fitting (figure E). It's important to install the fork head so the flat sides are facing the headlight housing bolt holes so the bolts have room and don't damage the fork cap.

• For the project bike, Dunk added some Teflon tape to the new fork cap threads to create a good seal. Then it's installed in the top of the fork and tightened down.

  Note: As the cap is tightened down it pulls the fork up and into place (figure F).

• Do the other fork the same way, and with both forks in place, tighten the forks down by slipping the brake drum back on, tap into place and tighten the drum down.

The new forks will give the bike better handling, which leads to a smoother ride. In the last segment the wheels and brand new tires go on.

RESOURCES :

The Eastwood Company

The Eastwood Company is a supplier of automotive-restoration parts, tools and supplies.

The Easthill Group, Inc.
The Eastwood Company
Website: www.eastwoodco.com

Eazyrizer Big Blue Motorcycle Lift (Driven Gear)
Driven Gear Inc.
Website: www.drivengear.com

RaceDeck Modular Flooring (SnapLock Industries)
SnapLock Industries
Website: www.racedeck.com

Restoration Parts (Custom Chrome)
Custom Chrome
Website: www.customchrome.com

Bias-Ply Whitewall Tires (Dunlop)

These tires are restoration correct 130/90-16 front and rear bias-ply whitewall tires.

Dunlop Tire Corp.
Website: www.dunlop.com

Norton Abrasives

Sandpapers, cleaners, abrasives and bodywork supplies.
Website: www.nortonautomotive.com

GUESTS :

William "Dunk" Dunkelberger
Restoration Coordinator / Mechanic
Harrly Hoggs & Piggletts
1409 Piney Rd.
Maryville, TN 37803
Phone: 865-681-7699
E-mail: hoggsandpiggletts@yahoo.com