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My bike has been in the shop for weeks getting a few things done (brake lines, chrome parts, etc). The latest delay came today when problems seemed to come up with putting my Kewel Metal Phat Fork tubes on. My Mechanic said that he followed the directions in the packaging from Kewel Metal but things don't match up. I am desperate for some advice, install pics, anything that would help get my bike back on the road. I am now to the point of having it put back together without the covers but am very frustrated because that was the whole point of the latest mods... front end!
 

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WTF

Let me know what happens, please. Mine should be delivered after being backordered for a few weeks. I will be installing them hopefully by next week. Hope it works out (for both of us)
 

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i m not a mechanic but i can take stuff apart and put it back together. that being said, ive done this exact job at least 3 times and its not that hard. it IS alot of stuff to remove and replace but it just aint that hard.
i ll bet your mechanic is doing something wrong but if thats not the case im sure the guys at kewl will straighten it out. i had a small issue with something i got from them and they just sent me a new part with almost no questions asked. you re in good hands with kewl.:bigthumbsup:
 

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strange

This is a very simple job to do, I've done mine twice I'm suprised a mechanic would say he's having problems. I'm no mechanic either but this is one of the easiest things I've done to my bike. Just takes common sense pretty much.
 

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I've had my on and off a couple times with know problems. The only 2 things I can remember from the 1st installation was that you need to make sure you have the upper and lowers identified properly - there is only a slight length difference and make sure the top and bottom of each is identified also. the tops and bottoms of each tube have different depth counter bores on the inner diameter. Just a thought.....
 

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Posted this on another thread. Been awhile since I installed them but this should be it.

I've had the Kewl Metal Fat fork kit on my 109 for a few years now. I also had them on my VTX. The install is straight forward and really very easy.

1) Remove front brake calipers.
2) Remove lower pinch bolts
3) Remove front axle
4) Remove lower triple tree pinch bolts
5) Remove upper tree pinch bolts
6) Slide fork legs out
7) Slide "O" rings onto lower part of fork tube. Slide Kewl metal lower tube onto fork leg.
8) Slide fork tube back into lower and upper trip trees.
9) Put in lower trip tree pinch bolts and snug up. Leave upper trip tree pinch bolts out for now since you need to install up cover still.

Upper Fork Covers

1) Remove the center nut that holds the upper trip tree to the neck. You should now be able to lift the upper trip tree off.
2) slide kewl rubber "O" rings onto upper fork.
3) now slide on the Top Kewl metal cover.
4) Put the upper trip tree back on sliding over the top of the fork tubes.
5) Put in the upper trip tree pinch bolts and snug them up.

Now you can go back and tighten pinch bolts to torque spec. Put your wheel back on and torque all bolts to spec.

I went from memory on this, it has been some time ago that I did the install on these but I can tell you it took me all of an hour or so to do. If your mechanic can not do this job, I suggest you find a new mechanic. Very easy install.
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