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  1. #1

    Default 2003 sporty - stuck seal between slider and tube, and bobbed rear fender question

    I cannot get the seal out between the fork tube and the fork slider. i have a manual, i have removed EVERY bolt and clip, and the hammer slide technique did not work with me and my neighbor pulling hard. i tried to drill into the seal to grab hold of it and that did not work.

    Also, i have shortened my rear fender by about six inches. I left it long enough to cover the stock under-the-fender support bracket (that in my diagram has no name or number), but i don't like looking at that bracket from behind. Can I get rid of it? Does it support the fender for a passenger load, or does it only provide rigidity for the rear of fender/tail light?

    Thank you and the seal is my main problem if you only can answer one.

  2. #2
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    Can you post a pic of what your talking about???

  3. #3

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  4. #4

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    on the fender question, I am not hard tailing the bike. i am keeping the shocks and full frame at fender. just cutting fender back.

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    Removed damper screw ? If so, you should be able to slide hammer the tube out. Even if the seal is stubborn, you can pull the tube and bushings through the seal.
    Heat the top of the slider with a heat gun or hair dryer to aid seal removal.

    Jim

  6. #6

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    i read heat somewhere else, but they were talking torches which i dont have and wouldnt want to do to the slider anyway. i'll try the heat gun.

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    can you confirm that you have removed the damper retaining screw right at the bottom of the fork slider,... pointing up in a recessed hole accessible after you either remove the axle clamp or through the hole when the forks are upside down,.... its the only thing that can stop them coming apart other than having the strength of a grandma !!

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    IF you had a Sportster shop manual you would know how to remove the seal.
    You need a book not the internet.

    Here you go.
    https://www.youtube.com/watch?v=WsETE8tzD-Q
    Last edited by Luky; 05-12-2019 at 11:10 AM.

  9. #9

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    confirmed that screw and the little washer are out

  10. #10

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    Luky, i don't see that ring or step or mention of it in my MANUAL.

  11. #11
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    ^^^^ So 19a and 20a are out and you can't get the tube out??^^^^^

  12. #12

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    correct

  13. #13
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    That diagram is for a 35mm fork, not a 39mm like you have. They're similar but not the same.

    I have come across a few fork seals over the years that were real motherfuckers to get out. Water getting in there was usually the culprit and created rust. I agree with the heat gun idea, and also if you have any aerokroil lubricant it wouldn't hurt to spray it down and let it set overnight then come back at with a heat gun and see if she'll pop loose.
    Last edited by BadMonkeyMW; 05-12-2019 at 4:00 PM.

  14. #14

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    Let’s see more photos of the fender. I too have an 03 anniversary and have considered something similar. Unsure about the support bracket. Good luck with the seals!

  15. #15

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    Thank you everyone for help. The heat gun loosened up the first tube, and I got the seal out. The second one I was able to get out easier, but I left it in the triple tree the entire time for stability and to be able to really pull the slider against the steady tube.

  16. #16

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    i just set the fender on there. in the first picture you can see the fender support that i am questioning if i need. if i dont need it, i have to cut the fender some more or fill in the screw hole.

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