Ironhead Front End Removal

Kevin has our ’77 Sportster on the table lift with the rear wheel locked in the vise and the Ironhead front end slightly lifted with a flat jack. After our preliminary inspection, we already know that this XL has a fork seal leak and has no pressure at the front brake lever.

In this video, Kevin will be cleaning, inspecting, and servicing this Ironhead front end as he addresses the front brake system and removes the fork tubes for rebuilding.

Prior to disassembly, Kevin feels for correct neck adjustment and inspects the front wheel. The neck bearings and adjustment both feel good and the rim appears to be spinning free and running true. The front master cylinder reservoir top cover is removed and the reservoir is cleaned thoroughly.

After adding fresh DOT 5 brake fluid, Kevin “burps” the front master cylinder and pumps up the front brake. If the brake lever had not pumped up so easily, Kevin might have needed to rebuild the front master cylinder and caliper.

The front brake system is also inspected for possible leaks before moving forward. We highly recommend that you bleed the system to remove all old fluid and to ensure that fresh fluid is in the lines. Next, Kevin gets the fork tubes reinstalled.

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