Join Date: Mar 2011
Location: South Central WI
I believe that I have it down to a science now, after having about every problem with them that a person could. I had to take my forks off and appart 3 times before I got it right. The first time was the initial install, the second time was a warranty replacement (old known seal issue, now resolved), and an out of spec part in my fork.
My suggestion would be to read the service manual (if you don't have one, you should get one) and the instructions that are included with the monotubes. Before you start, I would suggest getting a Motion Pro Fork Cap socket, otherwise you will need a 36mm socket that can handle 50-60 ft lbs.
I didn't remove the bars. All that I removed was the calipers, wheel, fender, speedo/tach, and ignition switch. I had to loosen the guage nacelle to be able to access the fork caps, but I didn't fully remove the halves (be very careful not to scratch you inner fairing to heck). Once you get the forks off, you will need a strap wrench (if you don't have the fixture that hold the forks in a vice), a long 6mm allen socket (or chop off a allen key and put into a 6mm socket), and an impact screwdriver set to remove the drain plug.
When I did my swap, I was also putting a 21 on, and changing out to chrome forks, so I had to pull seals and the bottoming cup. When my forks were put together at the factory, apparently one of the bottoming cups was not used (Friday build???), so I used the bottoming cup included in the kit. This turned out to be a very bad idea, as the bottoming cup included with the kit isn't the correct size for anything other than a 02-05.
I have a '09, so I don't have as good of set-up help for you, because I only had to lower 1". The kit has instructions on how to lower 1" or 2", to retain stock ride height you will have to use the 2" setting. I didn't think that mine had enough preload on the spring with the 3 c clip spacers (again 1" drop), so I put 4 in, and it was awesome. The monotube instructions state to put 5oz of 20 wt fork fluid. I highly suggest that you get some actual 20 wt fork fluid verses counting on the H-D oil. In addition to the extra c clip spacer, I also put 5.5 oz in.
Even though I had a ton of issues and had to pull my forks 3 times, I would do it again for the ride that I have now. I was really hating the 21 because it handled so bad before I got the forks working great. Don't let my post scare you, it is not a hard job, just time consuming. I have the process down to about 3 hours without rushing.
2012 FLHTCUSE7 - D&D Boss Fat Cat/SE Compact Heavy Breather/SEPST
2015 FLTRXS - D&D Boss FatCat/SE Compact Heavy Breather/SESTP
Last edited by ShortBus453; 09-08-2011 at 08:01 AM.