JIMS 5821 Instruction Sheet

No.5821-IS
I I n n s s t t r r u u c c t t i i o o n n S S h h e e e e t t F F o o r r T T o o o o l l N N o o . . 5 5 8 8 2 2 1 1
J J I I M M S S N N o o . . 5 5 8 8 2 2 1 1 F F o o r r k k C C a a p p I I n n s s t t a a l l l l a a t t i i o o n n T T o o o o l l i i s s d d e e s s i i g g n n e e d d
® ®
f f o o r r u u s s e e o o n n 4 4 9 9 m m m m F F o o r r k k T T u u b b e e s s
Note:
Always wear safety glasses or other face and eye protection such as a full
face shield. JIMS is not responsible for damage, injury, or
your work. JIMS cannot be held liable for the quality
and safety of your work.
OTHER TOOLS REQUIRED
• 19mm Allen socket JIMS No. 5827
FORK CAP REMOVAL INSTRUCTIONS
1. Refer to H-D ® Service Manual for removal of the Fork Cap. See JIMS
catalog or view online at www.jimsusa.com for other tools that may assist in this procedure.
2. Assemble lower halves (No.
Insert and hand tighten the two No.
still move. Slide the assembly upward until the triple clamp is contacted. Ensure that the two threaded holes
on the tops of the clamps are not obstructed and snug up the two SHCS evenly to prevent binding.
3. Insert a 1/2" socket extension through No.
separately), to the extension. Slide the two No.
and start into the two threaded holes on the lower clamps. Run the bolts down with either an air ratchet or by
hand until contact is made with the fork cap. Snug the bolts down slowly and evenly by hand.
4. Fit the Allen drive into the top of the fork cap and slowly turn counter clockwise. Back off the No.
slowly and evenly along with the fork cap until the fork cap is loose from the fork tube.
5. Back off the two No.
6. Disassemble the No.
FORK CAP THREAD ALIGNMENT PROCEDURE
To assemble without cross threading the fork cap threads it is necessary to locate and mark the position where the
threads between the cap and fork tube begin to engage.
1. With the spring spacer removed from the tube, install the Fork Cap and rotate
and/or hear the thread drop. Mark both cap and tube.
2. Rotate clockwise to ensure the cap begins to engage the threads at the marked position.
3. Repeat this procedure several times to ensure the cap engages correctly at the marked position.
Failure to correctly identify and mark the thread start point may result in cross threaded or damaged
components.
FORK CAP INSTALLATION INSTRUCTIONS
1. Refer to H-D Service Manual for installation of the Fork Cap. See JIMS catalog or view online at
www.jimsusa.com for other tools that may assist in this procedure.
2. Assemble lower halves (No.
Insert and hand tighten the two No.
still move. Slide the assembly upward until the triple clamp is contacted. Ensure that the two threaded holes
on the tops of the clamps are not obstructed and snug up the two SHCS evenly to prevent binding.
3. Insert a 1/2" socket extension through No.
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Division of Thiessen Products, Inc.
5821-2 5812-3
and No.
2019
2-1/2" Socket Head Cap Screws (SHCS) loosely so the assembly can
5821-1
5821-4
bolts slowly until spring pressure is removed.
5821
as required.
5821-2 5812-3
and No.
2019
2-1/2" Socket Head Cap Screws (SHCS) loosely so the assembly can
5821-1
®
) loosely onto the fork tube below the top triple clamp.
2126
and No. . Attach the Allen socket, JIMS No. 5827 (sold
5821-4
10 inch bolts through the holes on the No.
) loosely onto the fork tube below the top triple clamp.
2126
and No. . Attach the Allen socket JIMS No. 5827 (sold
5821-1
5821-4
counter
clockwise until you feel
Rev O
07-17
bolts
1 1