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How to Remove Ironhead Fork Cups

The Harley-Davidson Ironhead Sportster motorcycle has been produced continuously since 1957. Its popularity stems from its simple, yet powerful design and the fact that it easily lends itself to customization. A bad set of steering fork head bearings and cups may cause a shimmy or wobble at highway speeds. This wobble may cause excessive rider fatigue and accelerated tire wear. Replacing the fork cups is required when the bearings have worn past their expected service life. Changing the fork cups is a job you can do yourself to keep your Ironhead safe and easy riding.

Instructions

1

Support the motorcycle on a stand so that the front wheel is clear of the ground. Remove the front axle nut and lock washer. Loosen the fork slider cap nuts, disconnect the speedometer cable and remove the brake caliper.

2

Push the front axle out of the wheel hub and remove the front wheel. Take care not to lose the axle spacers and the speedometer gear drive. Remove the front fender.

3

Turn the fuel selector to the "Off" position and remove the fuel tank. Remove the front trim panel, headlight and front turn indicators. Remove the bolts holding the speedometer/tachometer unit and lay the assembly aside.

4

Remove the fork tube caps and loosen the steering head pinch bolts. Twist and remove the front fork tubes. Reinstall the fork tube caps to ensure that no fork oil is spilled.

5

Remove the upper fork stem end nut and pinch bolts. Remove the upper fork bracket. Pull the steering stem out of the frame. On models built before 1975 the steering head bearings are loose and will fall out when the steering stem is removed. There are 28 bearings: 14 on the top and 14 on the bottom. Do not intermix the bearings, and replace them in complete sets if required.

6

Drive out the fork bearing cup with a 3/4-inch-diameter hardwood rod and hammer. Tap all around the bearing cup from the inside of the stem so that neither the bearing cup nor the head tube is bent.

7

Fit the new fork bearing cups into the end of the head tube. Tap them into place slowly and squarely with a block of wood to prevent bearing damage from the hammer.

8

Reassemble the front end in the reverse order of dissasembly. Add fresh bearing grease on the fork cups to hold the loose bearings in place during reassembly.