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FL Softail Profile Low Front Suspension Kit
J002802013-08-08
GENERAL
Kit Number
54596-94
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Additional Parts Required
WARNING
Installation of any accessory suspension components can affect cornering clearance. This could distract the rider, causing loss of control and death or serious injury. (00431b)
This Profile® Low Front Suspension Kit cannot be used independently, and MUST be used with an appropriate rear suspension lowering kit. The installation of either a Profile Low Rear Suspension Kit, Part Number 54588-94, 54648-00A, or 54665-03, or a Rear Lowering Kit, Part Number 54001-04 is required.
See any Harley-Davidson dealer for application information regarding these kits, which are available separately.
Two new fork tube plug oil seals (Part Number 45733-48) will also be required. These are available from any Harley-Davidson dealer.
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.
Installation
Fork Spring Removal
1. Elevate and support the vehicle so the front tire is off the floor and the forks are fully extended.
NOTE
Remove the brake caliper from the fork slider. DO NOT remove the brake line from the caliper.
1Slider tube cap
2Spacer washer
3Oil seal
4Clamp bolt and washer
5Fork tube plug
6O-ring
7Fork spring
8Tight-wound end of spring
9Fork slider tube
10Fork slider
11Drain screw and washer
Figure 1. Front Fork
2. Remove the front wheel. See FRONT WHEEL: FLSTC/FLSTF/FLSTN in the Service Manual.
3. Remove the front fender. See FRONT FENDER in the Service Manual.
4. See Figure 1. Remove the slider tube cap (1), spacer (2) and oil seal (3) from the top of one fork side. Save the cap and spacer. The oil seal can be discarded.
5. Loosen the clamp bolt (4) and pull the fork from the brackets.
6. Repeat Steps 4 and 5 for the other fork side.
NOTE
Be careful not to damage the O-ring.
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)
7. See Figure 1. Remove the fork tube plug (5) and O-ring (6). Pull the spring (7) out of the slider tube (9). Remove the drain screw and washer (11), and drain the fork. Install the drain screw and washer, and tighten to 52-78 in-lbs (5.9-8.9 Nm).
8. Repeat Step 7 for the other fork side.
NOTE
The Profile® Low Front Suspension Kit requires a different amount of H-D TYPE E FORK OIL than is listed in the Service Manual.
NOTE
Measure the oil level from the top of the fork tube with the fork spring removed and the fork fully compressed.
9. See FRONT FORK OIL in the Service Manual, but substitute the measures below. Fill the forks with Harley-Davidson TYPE E FORK OIL:
  • 1986 through 1999 models:
  • 11.7 oz (345 cc) of oil, or
  • 5.2 inch (132 mm) from top of oil level to top of tube.
  • 2000 and later models:
  • 13.4 oz (396 cc) of oil, or
  • 4.1 inch (104 mm) from top of oil level to top of tube.
Fork Spring Installation
  1. Insert a new Profile Low spring (7) from the kit into each slider tube (9), with the tight-wound portion (8) toward the bottom of the fork slider.
    2. NOTE
    Be careful not to damage the O-ring.
  2. Install the fork tube plug (5) and O-ring (6) assembly into the slider tube and tighten securely. Be sure that one flat on each fork tube plug faces toward the inside of the fork.
  3. Insert both fork side assemblies up through the slider covers, the fork stem and bracket, and the upper bracket.
  4. Obtain two new oil seals (3), H-D Part Number 45733-48, and the spacer washers (2) and slider tube caps (1) saved earlier. Place an oil seal, followed by a spacer washer, onto each fork tube plug.
  5. Insert the threads of a slider tube cap through each washer and seal, and into the fork tube plugs. Tighten to 40-60 ft-lbs (54.2-81.3 Nm).
  6. Tighten the fork stem bracket clamp bolts (4) to 30-35 ft-lbs (40.7-47.5 Nm).
  7. Install the front fender. See FRONT FENDER in the Service Manual. Install the front wheel and brake caliper. See FRONT WHEEL: FLSTC/FLSTF/FLSTN in the Service Manual.
Jiffy Stand Removal/Installation
1. Move the jiffy stand to the retracted (up) position.
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)
2. See Figure 3. Unfasten the jiffy stand leg spring (A) from the vehicle. Remove the hex bolt (B), lock washer (C), flat washer (D) and leg stop (E) from the threaded end of the jiffy stand leg. Discard the jiffy stand leg, but retain all other components.
3. Clean and inspect the jiffy stand attaching parts and mounting bracket for wear or damage. If parts replacement is necessary, refer to the Jiffy Stand section of your Service Manual for replacement procedures.
WARNING
If leg stop is incorrectly installed, excessive wear can allow vehicle to fall when rested on jiffy stand, which could result in death or serious injury. (00479b)
4. Assemble the new jiffy stand leg assembly (2) from the kit to the mounting bracket on the motorcycle. Holding the jiffy stand at the full forward (down) position, install the leg stop (E) over the square end. Be sure the stamped "DOWN SIDE" text on the leg stop is facing down. Verify that the longer side of the leg stop faces the rear of the motorcycle (see Figure 2). Secure with the flat washer (D), lockwasher (C), and bolt (B) removed earlier.
1Longer side of leg stop faces rear of motorcycle
2Bolt and washers
3Front of motorcycle
4Rear of motorcycle
Figure 2. Leg Stop Orientation (Full Forward Position)
5. Install the jiffy stand leg spring (A). Tighten bolt (B) to 144-180 in-lbs (16.3-20.3 Nm).
6. Install the rubber bumper (3) from the kit into the hole on the raised tip of the jiffy stand leg.
7. Extend and retract the jiffy stand leg several times to verify proper operation. The stand should swing freely to the fully extended and fully retracted positions.
WARNING
The jiffy stand locks when placed in the full forward (down) position with vehicle weight on it. If the jiffy stand is not in the full forward (down) position with vehicle weight on it, the vehicle can fall over which could result in death or serious injury. (00006a)
WARNING
Be sure jiffy stand is fully retracted before riding. If jiffy stand is not fully retracted, it can contact the road surface causing a loss of vehicle control, which could result in death or serious injury. (00007a)
WARNING
Always park motorcycle on a level, firm surface. An unbalanced motorcycle can fall over, which could result in death or serious injury. (00039a)
8. Move the jiffy stand to the full forward (down) position. Carefully remove the support blocking from beneath the motorcycle frame and rest the motorcycle on the jiffy stand.
SERVICE PARTS
Figure 3. Service Parts: FL Softail Profile Low Front Suspension
Table 1. Service Parts Table
Item
Description (Quantity)
Part Number
1
Spring, front suspension (Profile® Low) (2)
54597-94
2
Jiffy stand assembly, low
50175-95
3
Bumper
62123-66A
Items mentioned in text, but not included in kit:
A
Jiffy stand leg spring
B
Bolt
C
Lockwasher
D
flat washer
E
Jiffy stand leg stop