JIMS 5821 User manual

IInnssttrruuccttiioonn SShheeeett FFoorr TTooooll NNoo.. 55882211
Rev O
07-17
No.5821-IS
11
555 Dawson Drive, Camarillo, CA 93012 Phone [phone] • Fax [phone]
Visit us on the we at WWW.JIMSUSA.COM or checkus out on Youtu e at JIMS USA
A Division of Thiessen Products, Inc.
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ffoorr uussee oonn 4499mmmm FFoorrkk TTuubbeess
Note: Always wear sa ety glasses or other ace and eye protection such as a ull
ace shield. JIMS is not responsible or damage, injury, or
your work. JIMS cannot be held liable or the quality
and sa ety o your work.
OTHER TOOLS REQUIRED
• 19mm Allen socket JIMS No. 5827
FORK CAP REMOVAL INSTRUCTIONS
1. Re er to H-D®Service Manual or removal o the Fork Cap. See JIMS®
catalog or view online at www.jimsusa.com or other tools that may assist in this procedure.
2. Assemble lower halves (No. 5821-2 and No. 5812-3) loosely onto the ork tube below the top triple clamp.
Insert and hand tighten the two No. 2019 2-1/2” Socket Head Cap Screws (SHCS) loosely so the assembly can
still move. Slide the assembly upward until the triple clamp is contacted. Ensure that the two threaded holes
on the tops o the clamps are not obstructed and snug up the two SHCS evenly to prevent binding.
3. Insert a 1/2" socket extension through No. 5821-1 and No. 2126. Attach the Allen socket, JIMS No. 5827 (sold
separately), to the extension. Slide the two No. 5821-4 10 inch bolts through the holes on the No. 5821-1
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 ork cap. Snug the bolts down slowly and evenly by hand.
4. Fit the Allen drive into the top o the ork cap and slowly turn counter clockwise. Back o the No. 5821-4 bolts
slowly and evenly along with the ork cap until the ork cap is loose rom the ork tube.
5. Back o the two No. 5821-4 bolts slowly until spring pressure is removed.
6. Disassemble the No. 5821 as required.
FORK CAP THREAD ALIGNMENT PROCEDURE
To assemble without cross threading the ork cap threads it is necessary to locate and mark the position where the
threads between the cap and ork tube begin to engage.
1. With the spring spacer removed rom the tube, install the Fork Cap and rotate counter clockwise until you eel
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. Re er to H-D Service Manual or installation o the Fork Cap. See JIMS catalog or view online at
www.jimsusa.com or other tools that may assist in this procedure.
2. Assemble lower halves (No. 5821-2 and No. 5812-3) loosely onto the ork tube below the top triple clamp.
Insert and hand tighten the two No. 2019 2-1/2” Socket Head Cap Screws (SHCS) loosely so the assembly can
still move. Slide the assembly upward until the triple clamp is contacted. Ensure that the two threaded holes
on the tops o the clamps are not obstructed and snug up the two SHCS evenly to prevent binding.
3. Insert a 1/2" socket extension through No. 5821-1 and No. 2126. Attach the Allen socket JIMS No. 5827 (sold

IInnssttrruuccttiioonn SShheeeett FFoorr TTooooll NNoo.. 55882211
Rev O
07-17
No.5821-IS
22
555 Dawson Drive, Camarillo, CA 93012 Phone [phone] • Fax [phone]
Visit us on the we at WWW.JIMSUSA.COM or checkus out on Youtu e at JIMS USA
A Division of Thiessen Products, Inc.
4
5
1
2
6
7
8
3
separately) to the extension. Slide the two No. 5821-4 10 inch bolts through the holes on the No. 5821-1
and start into the two threaded holes on the lower clamps. Run the bolts down with either an air ratchet or by
hand until near the end o the ork tube.
4. Place Fork Cap onto Allen socket and slowly hand tighten the No. 5821-4 bolts simultaneously until the spring
is compressed and the ork cap threads are inside o ork tube.
5. Continue tightening o the No. 5821-4 bolts by hand only until snug.
6. Turn 1/2" ratchet counter clockwise until you line up the marks on tube and cap (loosen the No. 5821-4 bolts
slightly i you cannot turn the cap).
7. Slowly turn the 1/2" ratchet clockwise. Make sure the threads engage and the cap should begin to tighten. The
No. 5821-4 bolts will begin to loosen when this happens. Tighten cap and torque to the speci ication listed in
the H-D Service Manual.
DO NOT orce the ork tube cap! Forcing the threads will result in damage to the cap, ork tube
or both! It is highly recommended to watch the video on the JIMS YouTube channel prior to using
this tool.
PARTS AVAILABLE SEPARATELY
NO. QTY. DESCRIPTION PART NO.
11 CROSSBAR 5821-1
21 HALF CLAMP 5821-2
31 HALF CLAMP, THREADED 5821-3
42 3/8-16 X 10” HEX HEAD 8” MIN THREAD 5821-4
52 WASHER, 3/8” 2031
62 5/8” BRASS WASHER 2126
72 5/16-18 X 2-1/2” SHCS, BLACK OXIDE 2019
82 5/16 FLAT WASHER 1216
91 INSTRUCTION SHEET 5821-IS
End Users
1/ ” Drive Ext.
JIMS No. 58 7
19mm Allen
Sold Seperately