Reassembling Front End

Here is a very useful set of directions to reassemble the front end on the Sportster. This is required after steering neck service and other instances when the fork tubes are removed from the triple trees. There is a very precise order in which things need to be tightened and not following that order can cause handling issues that did not exist prior to dis-assembly. The issues may be minor like a slight pull to the side or more severe like poor handling on uneven pavement.
The following list assumes that the fork tubes are perfectly straight and are exactly the same length. If not, then those things need to be addressed and are outside of the scope of this article. This also assumes the fork tubes are out of the triple clamps.
These instructions are provided from the wisdom of Steve Ellingson a.k.a. Crazy Steve of xl-list and are printed here with his permission. Thanks, Steve!
If the steering neck bearing adjustment is suspect begin at step 1, otherwise begin with step 3

1. Loosen the pinch bolt on the top triple clamp
2. Loosen the stem bolt, but don't remove it
3. Slip the fork tubes into the triple clamps and set the height exactly the same on both tubes. FSM recommends about 1/2" (11mm - 13mm)
4. Tighten the lower triple clamp pinch bolts to specified torque
5. Tighten the upper triple clamp pinch bolts to specified torque
6. Test fit the wheel axle. It should fit without having to force it. No binding at all should occur. If that's not the case go back to the beginning and start over
7. Install the wheel and torque the axle and axle pinch bolt to specs. Remember to torque the axle pinch bolt last.
8. Install the fender

If steering neck bearing adjustment is suspect follow these steps, otherwise you are done - test ride it.

1. Loosen lower triple clamp pinch bolts
2. Adjust fallaway of the front end per the FSM if needed
3. Tighten the stem pinch bolt to proper torque per FSM
4. Tighten the lower triple clamp pinch bolts to proper torque per FSM
5. Test ride 

If you run a fork brace, follow the instructions provided by the fork brace manufacturer for installation and install it after you are satisfied with the test ride results.