Black Triple Clamp Kit
J020782006-10-11
GENERAL
Kit Number
46169-02
Models
For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
WARNINGRider and passenger safety depend upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333b)
NOTE
This instruction sheet references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer.
Removal
- Remove headlamp and mounting block according to applicable Service Manual instructions.
- Remove handlebars, risers, front brake caliper, brake line, wheel and front fender according to applicable Service Manual instructions.
- Remove the slider tube caps, spacers and oil seals from the top of both fork sides.
- Remove fork stem cap, nut and lockwasher. Loosen the lower triple clamp pinch bolts and pull the fork sides from the brackets.
Installation
- See Figure 1. Install lower triple clamp cover (6).
- Install stem and bracket assembly (4) as shown.
- Install dust shield (10) and bearing assembly (8 and 9) as shown.
- Seat steering head by tightening bearing assembly to 40 ft-lbs (54.2 Nm). Loosen and then retorque bearing assembly to 72 in-lbs (8.1 Nm).
- Install fork legs through fork stem assembly according to applicable Service Manual instructions.
- Place upper triple clamp in position on stem and fork legs Reinstall slider tube caps, spacers and oil seals.
- Install the lower triple clamp pinch bolt. Tighten to 25-30 ft-lbs (33.9-40.7 Nm).
- Install fork stem lockwasher (2) and fork stem nut (3) Tighten to 30-35 in-lbs (3.4-4.0 Nm).
- Reinstall front fender, wheel, caliper, handlebars and headlamp assembly. Do not reconnect clutch cable until front end fall-away has been checked and adjusted.
- Adjust fall-away according to applicable Service Manual instructions.
SERVICE PARTS
Figure 1. Service Parts: Black Triple Clamp Kit
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
1 | Screw w/lockwasher (2) | 2823 | 8 | Nut, bearing | 48332-48B | |
2 | Lockwasher, fork stem | 45717-63 | 9 | Bearing | 48345-60 | |
3 | Nut, fork stem | 45718-00 | 10 | Cover, upper dust | 48361-80 | |
4 | Assembly, stem and bracket, black | 46105-02 | 11 | Bushing, handlebar riser (4) | 56156-86 | |
5 | Bracket, upper, black | 46108-02 | 12 | Spacer, handlebar riser (2) | 56153-73 | |
6 | Cover, lower triple clamp, black | 46117-02 | 13 | Lockwasher, 7/16 inch (2) | 7039 | |
7 | Bolt, 7/16-20 x 1-1/4 inch (2) | 4729 | ||||
Items mentioned in text, but not included in kit: | ||||||
A | Fork stem cap | |||||