FLHR (ROAD KING) FRONT END LOWERING KIT
J025552007-11-30
GENERAL
Kit Number
54599-02
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).
Additional Parts Required
WARNINGThis kit is not designed to be used with Sidecar installed. Any attempt to use this front suspension kit with sidecar can adversely affect stability and handling. (00430c)
WARNINGThis Front End Lowering Kit cannot be used independently. It must be used with an appropriate Low Rear Suspension Kit or handling and cornering can be affected, which could distract the rider, causing loss of control and death or serious injury. (00429b)
Proper installation of this kit also requires the following special tools: Fork Tube Holder (HD-41177), Fork Seal/Bushing Tool (HD-34634), Front Fork Oil Level Gauge (HD-59000B) and Fok Spring Compressing Tool (HD-45966).
Proper installation of this kit may also requires the replacement of the following parts:
Table 1. Replacement Parts
Item (Quantity) | Part Number |
|---|---|
O-ring (2) | 45845-77 |
Quad ring seal (2) | 45733-48 |
Fork tube bushing (2) | 45866-84 |
Wear ring | 45859-77A |
Slider bushing (2) | 45940-84 |
Fork oil seal (2) | 45875-84A |
Screw with copper crush washer, 6 mm (2) | 45405-75A |
Harley-Davdison®Fork oil | 99884-80 |
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
- Refer to the appropriate Service Manual and remove the front fender, wheel and brakes.
- Refer to the appropriate Service Manual and remove the front forks.
INSTALLATION
Left and Right Side Fork Disassembly
| 1. | Obtain right fork assembly removed in earlier step. | |
| 2. | Remove nuts, lockwashers, flat washers and axle holder from studs at end of fork slider. | |
| 3. | See Figure 2. Install fork in Fork Tube Holder (HD-41177) as follows: a. Clamp end of tool (1) in vise in a horizontal position. b. With the fork cap bolt topside, clamp fork tube between rubber pads (2) on inboard side of tool. Tighten knobs (3) until fork tube is securely held. NOTE Refer to Figure 10 for Steps 4 - 17. | |
| WARNING Wear safety glasses or goggles when servicing fork assembly. Do not remove slider tube caps without relieving spring preload or caps and springs can fly out, which could result in death or serious injury. (00297a) | ||
| 4. | Remove fork cap bolt (A) from fork tube plug. Remove quad ring seal (B). Save bolt but discard quad ring seal. | |
| 5. | Slowly remove fork tube plug (C) from fork tube (H). Be aware that fork tube plug is under spring-pressure, so have a firm grasp on plug as the last thread is turned. | |
| 6. | Pull up on fork slider (V) to compress fork assembly, which causes the damper rod to protrude from the top of the fork tube (H). | |
| 7. | Remove the fork spring (2) from the fork tube. | |
| 8. | Remove fork assembly from fork tube holder. Turn fork upside down and drain fork oil into drain pan. For best results, slowly pump fork tube and slider at least 10 times. | |
| 9. | Install fork spring back into fork tube. | |
| 10. | Put a shop rag on the floor. Turn the fork assembly upside down and press the end of the spring against the rag. Compress the spring and remove the 6 mm screw (S) from end of fork slider (VS). Use air impact wrench for best results. Discard 6 mm screw (S) and copper crush washer (R). | |
| 11. | Remove fork spring (2) and damper tube (3) from fork tube. Discard fork spring. | |
| 12. | Remove wear ring (T) and rebound spring (4) from damper tube. Save wear ring but discard rebound spring and damper tube. | |
| 13. | Using pick tool, remove retaining clip (I) between fork slider (V) and fork tube (H). Do not expand or stretch retaining clip to remove from fork tube or clip may be damaged. NOTE To overcome any resistance, use the fork tube as a slide hammer: Push fork tube into fork slider and then pull it outward with a moderate amount of force. Repeat this sequence until fork tube separates from fork slider. | |
| 14. | Remove fork tube from fork slider. | |
| 15. | Slide fork oil seal (J), slider spacer (K) and slider bushing (M) off end of fork tube. Discard fork oil seal and slider bushing. | |
| 16. | Gently pry at split line to expand fork tube bushing (L), and then remove from groove at end of fork tube. Discard fork tube bushing. | |
| 17. | Remove the lower stop (U) from the fork slider. |
Left Side Fork Assembly
NOTICE
Exercise caution to avoid scratching or nicking fork tube. Damaging tube can result in fork oil leaks after assembly. (00421b)
NOTE
Refer to Figure 10 for the following procedure.
| 1. | Coat new fork tube bushing (45866-84, not included) ID with clean fork oil. Expand fork tube bushing at split line only as far as required to slip over end and into groove of fork tube. | |||||||||||||
| 2. | Slide new damper cartridge (5) into new fork tube (10), so the cartridge end drops through hole at bottom of fork tube. Install lower stop at end of damper cartridge. | |||||||||||||
| 3. | Install fork slider (O) in fork tube holder. Slide fork tube (10) into fork slider. | |||||||||||||
| 4. | Coat fork tube bushing (L) ID with clean fork oil. Slide fork tube bushing down fork tube (H). | |||||||||||||
| 5. | Slide slider spacer (K) down fork tube until it contacts fork tube bushing. NOTE Place masking tape over edge of fork tube to avoid damaging lip of fork oil seal during installation. | |||||||||||||
| 6. | Coat the new fork oil seal (J, 45875-84A, not included) ID with clean fork oil. With the lip of garter spring side facing down (toward the fork slider), slide fork oil seal down the fork tube until it contacts the slider spacer. Remove masking tape from edge of fork tube. |  Figure 3. Fork Seal/Bushing Tool (HD-34634)  Figure 4. Install Fork Oil Seal | ||||||||||||
| 7. | See Figure 3. Obtain the Fork Seal/Bushing Tool (HD-34634) and proceed as follows: a. Slide the fork seal installer down the fork tube until it contacts the fork oil seal. b. See Figure 4. Using the tool like a slide hammer, drive fork oil seal (with slider spacer and guide bushing) down the fork tube until retaining clip groove is visible in fork slider ID. c. Slide the retaining clip (I) down the fork tube until it contacts the fork oil seal. Install retaining clip in the fork slider groove. Do not expand or stretch retaining clip to install on fork tube or clip may be damaged. NOTE Ensure the fork spring is installed with dense section of coils to the bottom. | |||||||||||||
| 8. | Obtain shorter fork spring (1) from the kit. Install new fork spring into fork tube. | |||||||||||||
| 9. | Remove fork assembly from fork tube holder. | |||||||||||||
| 10. | Place a shop rag on the floor, and turning fork assembly upside down, press end of spring against rag. | |||||||||||||
| 11. | Install new screw (S) with copper crush washer (R, 45405-75A, not included). Slide screw through hole at bottom of fork slider and start into end of damper cartridge. | |||||||||||||
| 12. | Compress spring to prevent rotation of damper cartridge and tighten the screw to 15–24 N·m (11–18 ft-lbs). | |||||||||||||
| 13. | Remove fork spring from fork tube. | |||||||||||||
| 14. | With the fork tube topside, clamp fork slider (not the fork tube) into fork tube holder. NOTE Install the drain screw at the bottom of the fork slider, if removed. Tighten the screw to 8–11 N·m (72–96 in-lbs). | |||||||||||||
| 15. | Fill the fork tube as follows: a. Thread jam nut onto damper rod until it fully seats on shoulder. b. See Figure 9. Thread extension tool onto end of damper rod. c. Pour 5 ounces (147.9 ml) of Harley-Davidson Type E Fork Oil into the fork tube. d. Slowly pump the damper rod until resistance is felt and then pump five more times. e. Place the damper rod in the fully bottomed position. f. Pour another 6 ounces (177.5 ml) of fork oil into the fork tube. g. Remove the extension tool from the end of the damper rod. |  Figure 5. Front Fork Oil Level Gauge (HD-59000B)  Figure 6. Remove Excess Fork Oil | ||||||||||||
| WARNING Incorrect amount of fork oil can adversely affect handling and lead to loss of vehicle control, which could result in death or serious injury. (00298a) | ||||||||||||||
| 16. | Adjust the fork oil level, so that it is 156 mm (6.14 in) from the top of the fork tube with the fork tube compressed and the fork spring removed. Proceed as follows: a. See Figure 5. Obtain the Front Fork Oil Level Gauge (HD-59000B). b. Loosen thumbscrew on metal ring and move it up or down the rod until the bottom of the ring is 156 mm (6.14 in) from the bottom of the rod. Tighten thumbscrew. c. Push the handle on the cylinder all the way in. d. See Figure 6. Insert rod into top of fork tube until metal ring rests flat on top of fork tube. e. Pull handle to remove fork oil from fork tube. Observe fork oil through transparent tube to ensure oil is being drawn from cylinder. f. Remove rod from fork tube. Push handle into cylinder to eject excess fork oil into suitable container. g. If necessary, repeat Steps 16(c) through 16(f). Level is correct when no fork oil is observed being drawn through transparent tube. | |||||||||||||
| 17. | Install fork spring into the fork tube with the dense end down. | |||||||||||||
| 18. | Pull up on fork slider to compress fork assembly, which causes the damper rod and spring to protrude from the top of the fork tube. | |||||||||||||
| 19. | Thread extension tool onto end of damper rod. NOTE Do not use an air impact wrench to adjust the fork spring compression tool. | 
Figure 7. Fork Spring Compressing Tool (HD-45966) 
Figure 8. Compress Fork Spring  Figure 9. Pump Damper Rod Extension Tool | ||||||||||||
| WARNING Wear safety glasses or goggles when removing or installing spring. Spring tension can cause spring, attached components and/or hand tools to fly out which could result in death or serious injury. (00477c) | ||||||||||||||
| 20. | See Figure 7. Install fork spring compression tool as follows: a. Clamp tool in vise in a vertical position with length adjustment screw (2) topside. b. Pull up on fork slider to compress fork assembly. c. Place hole at bottom of fork slider over post (5) at bottom end of tool. d. Place flat washer (Item G, Figure 10 ), rounded side up, over the damper rod extension tool and on top of spring. Place spring seat (Item F, Figure 10 ), concave side up, on top of the flat washer. With the smaller OD topside, place spring compressor (4) over spring seat and flat washer. e. Adjust tool as necessary until three retaining pins (3) engage blind holes in spring compressor (4). Turn length adjustment screw counterclockwise to lengthen and clockwise to shorten. f. Turn retaining pins as necessary to lock position of spring compressor. g. Turn length adjustment screw in a clockwise direction to compress spring. | |||||||||||||
| 21. | After a number of turns, pull up on extension tool to raise damper rod. If threaded portion of rod cannot be pulled completely out of spring, compress spring further. Repeat until threaded portion of rod can can be pulled completely out of spring. | |||||||||||||
| 22. | Remove extension tool, while holding the damper rod. | |||||||||||||
| 23. | Thread new locknut (7) onto the damper rod until it contacts the shoulder. | |||||||||||||
| 24. | Install new O-ring (D, 45845-77, not included) onto fork tube plug. Thread fork tube plug onto threaded end of rod until it bottoms. Turn jam nut counterclockwise until it makes firm contact with the fork tube plug. Tighten jam nut to 18–27 N·m (13–20 ft-lbs). | |||||||||||||
| 25. | Turn the length adjustment screw at top end of fork spring compressing tool counterclockwise to release tension on fork spring. Loosen retaining pins and remove spring compressor. Remove fork assembly from tool and remove tool from vise. | |||||||||||||
| 26. | Install fork tube holder in vise. Clamp fork tube into fork tube holder. NOTE Do NOT overtighten or O-ring damage may occur. | |||||||||||||
| 27. | Thread new fork tube plug (6) into fork tube. Tighten fork tube plug to 30–79 N·m (22–59 ft-lbs). | |||||||||||||
| 28. | Install new quad ring seal (B, 45733-48, not included) onto fork cap bolt. Thread fork cap bolt (A) into fork tube plug to prevent loss of fork oil while handling. | |||||||||||||
| 29. | Remove the fork assembly from the fork tube holder. |
Right Side Fork Assembly
NOTICE
Exercise caution to avoid scratching or nicking fork tube. Damaging tube can result in fork oil leaks after assembly. (00421b)
NOTE
Refer to Figure 10 for the following procedure.
| 1. | Coat new fork tube bushing (45866-84, not included) ID with clean fork oil. Expand fork tube bushing at split line only so far as required to slip over end and into groove of fork tube. | |
| 2. | Obtain new damper tube (3). If necessary, install new wear ring (T, 45859-77A, not included) in groove at top of new damper tube. Install new rebound spring (4) and install on opposite end of damper tube. | |
| 3. | With the wear ring topside, slide new damper tube (3) into fork tube, so that tube end drops through hole at bottom of fork tube (H). Install lower stop (U) at end of damper tube. | |
| 4. | Install fork slider (V) in fork tube holder. Slide fork tube into fork slider. | |
| 5. | Coat slider bushing (M) ID with clean fork oil. Slide slider bushing down fork tube. | |
| 6. | Slide slider spacer (K) down fork tube until it contacts slider bushing. NOTE Place masking tape over edge of fork tube to avoid damaging lip of fork oil seal during installation. | |
| 7. | Coat the new fork oil seal (J, 45875-84A, not included) ID with clean fork oil. With the lip of garter spring side facing down (toward the fork slider), slide fork oil seal (J) down fork tube until it contacts the slider spacer. Remove masking tape from edge of fork tube. | |
| 8. | See Figure 3. Obtain the Fork Seal/Bushing Tool (HD-34634) and proceed as follows: a. Slide the fork seal installer down the fork tube until it contacts the fork oil seal. b. See Figure 4. Using the tool like a slide hammer, drive fork oil seal (with slider spacer and guide bushing) down the fork tube until retaining clip groove is visible in fork slider ID. c. Slide the retaining clip (I) down the fork tube until it contacts the fork oil seal. Install retaining clip in the fork slider groove. Do not expand or stretch retaining clip to install on fork tube or clip may become bent or distorted. NOTE Ensure the fork spring is installed with dense section of coils to the bottom. | |
| 9. | Obtain longer fork spring (2). Install new fork spring into fork tube. | |
| 10. | Remove fork assembly from fork tube holder. | |
| 11. | Place a shop rag on the floor, turn fork assembly upside down and press end of spring against rag. | |
| 12. | Install new screw (S) with copper crush washer (R, 45405-75A, not included). Slide screw through hole at bottom of fork slider (V) and start into end of damper tube. | |
| 13. | While compressing spring to prevent rotation of damper tube, tighten the screw to 15–24 N·m (11–18 ft-lbs). | |
| 14. | Remove fork spring from fork tube. | |
| 15. | With the fork tube topside, clamp fork slider (not the fork tube) into fork tube holder. NOTE Install the drain screw at the bottom of the fork slider, if removed. Tighten the screw to 8–11 N·m (72–96 in-lbs). | |
| 16. | Pour 11.1 ounces (328 ml) of Harley-Davidson Type E Fork Oil into the fork tube. | |
| 17. | Adjust the fork oil level, so that it is 125 mm (4.92 in) from the top of the fork tube with the fork tube compressed, the main spring removed and the blow valve installed. Proceed as follows: a. See Figure 5. Obtain the Front Fork Oil Level Gauge (Part Number HD-59000B). b. Loosen thumbscrew on metal ring and move it up or down the rod until the bottom of the ring is 125 mm (4.92 in) from the bottom of the rod. Tighten thumbscrew. c. Push the handle on the cylinder all the way in. d. See Figure 6. Insert rod into top of fork tube until metal ring rests flat on top of fork tube. e. Pull handle to remove fork oil from fork tube. Observe fork oil through transparent tube to ensure oil is being drawn from cylinder. f. Remove rod from fork tube. Push handle into cylinder to eject excess fork oil into suitable container. Dispose of waste properly. g. If necessary, repeat Steps 17(c) through 17(f). Level is correct when no fork oil is observed being drawn through transparent tube. | |
| 18. | Install fork spring into the fork tube with the dense end down. NOTE Do NOT overtighten or O-ring damage may occur. | |
| 19. | Install new O-ring (D, 45845-77, not included) onto fork tube plug (B). Compressing fork spring with end of fork tube plug, thread fork tube plug into fork tube. Tighten fork tube plug to 30–79 N·m (22–59 ft-lbs). |
Fork Installation
| 1. | Remove fork cap bolt from front fork. | |
| 2. | Refer to the appropriate Service Manual and install the front forks. | |
| WARNING After repairing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a) | ||
| 3. | Refer to the appropriate Service Manual and install the front fender, wheel and brakes. |
SERVICE PARTS
Figure 10. Service Parts for Profile Low Front End Lowering Kit
Table 2. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
Fork spring service kit | 54134-02 | |
1 |
| Not Sold Separately |
2 |
| Not Sold Separately |
3 |
| Not Sold Separately |
4 |
| Not Sold Separately |
5 | Damper cartridge | 46269-02 |
6 | Fork tube plug | 46229-02 |
7 | Jam nut | 46262-02 |
8 | Spring seat | 46236-02 |
9 | Washer, flat | 46237-02 |
10 | Fork tube | 45972-02 |
11 | Lower stop | 46238-02 |
Items mentioned in text, but not included in kit: | ||
A | Fork cap bolt (2) | |
B | Quad ring seal (2) | |
C | Fork tube plug | |
D | O-ring (2) | |
E | Washer, flat (2) | |
F | Lockwasher (2) | |
G | Nut (2) | |
H | Fork tube | |
I | Retaining clip (2) | |
J | Fork oil seal (2) | |
K | Slider spacer (2) | |
L | Bushing, fork tube (2) | |
M | Bushing, slider (2) | |
N | Axle holder | |
O | Fork slider, left | |
P | Washer, flat (2) | |
Q | Plug (2) | |
R | Washer, copper, crush (2) | |
S | Screw, 6 mm (2) | |
T | Wear ring | |
U | Lower stop | |
V | Fork slider, right | |