View Full Version : broken 1200S fork cap

02-18-2014, 10:18 PM
The bike is a 96 sportster sport with the cartridge type front forks. The adjuster dial broke off and i have a replacement cap, but am stumped on how to get it off. I unscrewed it all the way and it must have some internal threading because it wont come off all the way. I'm going to try and put some pictures to help explain. One is of it off, but still attached (bad light, sry) the other is of the new one.

02-19-2014, 7:05 AM
You need the FSM, a fork spring compressor and fork tube clamp. Basically you need to compress the spring, and get at the jam nut between the cartridge rod and fork cap. You need to completely remove the fork from the bike, drain the oil, replace seals and oil, bleed the cartridge of air, etc. Might consider rebuilding both sides while you are at it.

02-19-2014, 8:15 AM
the regular sportster manual has the S model fork instructions in it. It will all make sense when you see the manual.

02-19-2014, 11:25 AM
I can snap a pic of the FSM for S model cartridge forks

Mine's a 99.

02-19-2014, 12:22 PM
I can snap a pic of the FSM for S model cartridge forks

Mine's a 99.

That would be awesome, im not a fan of buying tools if i can make them.

02-19-2014, 4:50 PM
Cool, gimme an hour and I'll take a pic when I get home from work

------ OK, here you go: