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CHROME BILLET TRIPLE TREE KIT
J021102008-01-15
GENERAL
Kit Number
45748-01A and 46290-04
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).
NOTE
Windshields cannot be installed with this kit installed.
Additional Parts Required
This kit requires installing a front braided brake line kit, sold separately, for your model motorcycle:
Loctite ® 243 Threadlocker and Sealant (blue) (P/N 99642-97)
  • 1999 and later FXST requires kit 44813-00A
  • 1984 - 1999 FXSTC and 1993 - 2003 FXDWG require kit 45206-97B
  • 1999 and later FXSTB requires kit 45264-98B
This kit requires installing a steering-stop kit, sold separately, for your model motorcycle:
  • 2000 and later FXST and FXTB require kit 46072-02
  • 1984 - 1999 FXST and FXSTC require kit 46073-02
  • 1993 - 2003 FXDWG requires kit 46074-02
WARNING
Rider 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.
Kit Contents
See Figure 3 and Table 1.
Stock Fork Removal
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a)
  1. Remove the seat according to the Service Manual instructions for your model motorcycle.
  2. Disconnect the battery cables, negative cable first.
  3. Remove the fuel tank according to the Service Manual instructions.
  4. Disconnect the wire harnesses, from the handlebar and fork assembly, at the connector on the frame backbone.
  5. Elevate the front end of the motorcycle high enough to allow front-fork removal.
  6. Remove the front wheel according to the Service Manual instructions
  7. Remove the fork tubes from the triple-tree clamps according to the Service Manual instructions.
  8. Drain the brake fluid from and remove the front brake line between the brake master cylinder and the front brake caliper.
  9. Remove the headlamp assembly from the stock lower triple-tree clamp.
  10. Remove the handlebar from the risers.
  11. Remove the risers and riser rubber bushings from the upper triple-tree clamp.
  12. Remove the stock steering stem and brackets according to the Service Manual instructions.
Billet Triple Tree Installation
1. See the Service Parts illustration. Pack the two new bearings (10) with grease.
2. Slide the small lower dust shield (11) and a new bearing (10) onto the fork stem as shown.
3. Insert the fork stem/billet lower triple tree (12) into the steering head on the frame from the bottom upward.
4. Slide a new bearing (10) and the larger dust shield (9) onto the fork stem, as shown.
NOTE
Over-tightening the adjusting nut causes excessive and premature bearing wear.
5. See Figure 3 and Figure 1. Thread the adjusting nut (8) onto the fork stem, tapered side upward, flat side against the dust shield (9). Tighten the adjusting nut until the bearings show no lateral motion in their bearing cups, but not so tight that the fork stem does not move easily and freely from side to side.
Figure 1. Adjusting Nut (tapered side)
6. Place the upper billet triple tree clamp (6), with the large diameter bore up and the tapered bore down, against the tapered side of the adjusting nut on the fork stem.
7. Slide the Belleville washer (4), concave side down, onto the fork stem.
WARNING
Properly adjust fork stem bearings. Improper adjustments can adversely affect stability and handling, which could result in death or serious injury. (00301c)
8. See Figure 3 and Figure 2. Thread the new fork stem nut (3), stepped-side down, onto the fork stem. Finger tighten only at this time.
Figure 2. Fork Stem Nut (stepped side down)
9. Insert the forks through the lower triple tree clamp and into the upper triple tree clamp.
10. Fasten the forks to the upper triple-tree clamp using the stock seal, washer, and slider-tube cap (bolt). Torque the slider-tube cap to 14.9–29.8 N·m (11–22 ft-lbs).
11. Fasten the front wheel to the front fork according to the Service Manual instructions.
12. Adjust the adjusting nut (8) to set steering-head fallaway according to the Service Manual instructions. Refer to the STEERING HEAD BEARINGS section in the appropriate Service Manual.
13. Torque the stem nut (3) to 54.2–61 N·m (40–45 ft-lbs).
14. See Figure 3. Apply Loctite 242 (blue) to the six lower triple tree pinch bolts (14).
15. Loosely fasten the pinch bolts to the lower triple tree clamp as shown. Torque the bolts in these steps:
a. Middle, then top, then bottom bolts to 9 N·m (80 in-lbs).
b. Middle, then top, then bottom bolts to 11.5 N·m (100 in-lbs).
c. Middle, then top, then bottom bolts to 13.5–14.7 N·m (120–130 in-lbs) each.
NOTE
The steering stops may need to be pressed into the triple tree clamp far enough that the steering stop screws (14) can thread into the steering stops from the bottom of the tripletree clamp.
16. Install the steering stops:
a. Insert steering stops (13) in the left and right side holes on the top of the lower triple tree clamp.
b. Apply Loctite 242 (blue) to the steering-stop screw (15) provided in the steering stop kit.
c. Fasten the stops to the triple tree clamp with the screw through the bottom of the lower triple-tree clamp. Torque the screws to 13.5 N·m (120 in-lbs).
NOTE
On FXDWG models, the steering stops are not functional other than to fill the holes on, and to provide a brake line Pclip fastener on the bottom of, the lower triple tree. The tops of properly installed steering stops on FXDWG models must be flush with the top of the lower triple tree.
17. See Figure 3. Install the O-ring (2) on the stem nut cover (1).
18. Apply rubbing alcohol to the O-ring on the stem nut cover.
19. Press the stem nut cover into position on top of the upper triple tree clamp.
20. Install the stock riser rubber bushings on the upper triple tree clamp according to the Service Manual instructions.
NOTE
A ground strap fastens between the right riser and the P-clip on the back-right side of the lower triple tree clamp.
21. Fasten the stock risers and one end of the ground strap to the upper triple tree clamp according to the Service Manual instructions.
22. Install the handlebars according to the Service Manual instructions.
23. Fasten the headlight assembly to the top of the lower triple tree clamp using the screw (16) from this kit and stock lockwasher. Apply Loctite 242 (blue) to the screw. Insert the screw upward through the bottom of the clamp. Torque the screw to 3.9–40.7 N·m (25–30 ft-lbs).
24. Install the braided front brake line kit (sold separately). with these exceptions to the brake line-kit installation instructions:
  • Use the self-tapping screw (7) from this kit to fasten the loose end of the ground strap and the top P-clip to the back-right side of the upper triple tree clamp. Torque the screw to 2.3 N·m (20 in-lbs).
  • Fasten the brake line bottom P-clip to the bottom of the lower triple tree clamp using the right-side steering-stop screw (15). Torque the screw to 13.5 N·m (120 in-lbs).
  1. Route the handlebar wiring through the hole (5) in the front-center of the upper triple tree clamp.
  2. Connect the headlight and handlebar wiring to the main wiring harness.
  3. Install the fuel tank according to the service service manual procedures.
  4. Turn the handlebars full right and left. Check that the:
  • Handlebars and triple tree clamps do not contact the fuel tank.
  • Steering stops function properly.
  • Wiring and brake line are not pinched or kinked in the steering assembly.
  • The fork lock functions properly.
25. Grease the steering head through the grease Zerk according to the service service manual procedures.
WARNING
Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a)
26. Connect the battery cables, positive cable first.
WARNING
After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b)
27. Install the seat.
NOTE
Allow all Loctite to cure for 24 hours before operating the vehicle.
Service Notes
Perform the following service on your vehicle every 2,500 miles (4,000 Km) after installing this kit:
  • Check the steering-head bearings for steering-head fall-away and adjust according to the service manual instructions. Refer to the STEERING HEAD BEARINGS section in the appropriate service manual.
  • Grease the steering head according to the service manual instructions.
SERVICE PARTS
Figure 3. Service Parts: Chrome Billet Triple Tree Kit
Table 1. Service Parts Table: Chrome Billet Triple Tree Kit
Item
Description (Quantity)
Part Number
Item
Description (Quantity)
Part Number
1
Stem nut cover
29799-01
10
Steering head bearing (2)
48345-60
2
O-ring
11188
11
Lower dust shield
48365-48A
3
Fork stem nut
45718-60
12
Fork stem
Not Sold Separately
4
Belleville washer
37000-00
13
Steering stop (2)
2000 and later FXST/B
1984-1999FXST/C
1993-2003 FXDWG
Sold Separately
46072-02
46073-02
46074-02
5
Handlebar wire harness opening
14
Socket head capscrew
94314-91T
6
Upper triple tree
Kit 45748-01A
Kit 46290-04
Sold Separately
45615-01
46291-04
15
Sold with Item 12
7
Self-tapping screw
4091
16
Socket head capscrew
94358-91T
8
Adjusting nut
48324-00
17
Lower triple clamp (includes fork stem, item 12)
9
Upper dust shield
48361-80
Kit 46290-04
Kit 45748-01A
46341-04
46340-04