FLSTS (Springer) Front End Kit
J016862006-08-09
GENERAL
Kit Number
46194-00
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
We recommend this kit be installed by a factory trained technician at an authorized Harley-Davidson Dealership.
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.
WARNINGModifying the Springer front end can adversely affect stability and handling, which could result in death or serious injury. (00299a)
WARNINGWhenever a wheel is installed and before moving the motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. (00284a)
NOTE
This kit is designed for use with 16 inch front wheel. Do not use any other front wheel with this kit.
WARNINGOnly Touring Harley-Davidson Motorcycles are suitable for sidecar use. Consult a Harley-Davidson dealer. Use of motorcycles other than Touring models with sidecars could result in death or serious injury. (00040a)
INSTALLATION
Rigid Fork
Refer to the applicable Service Manual for Rigid Fork Assembly and Installation procedures.
Lower Springer
Refer to the applicable Service Manual for Lower Springer Assembly and Installation procedures.
Springer Steering Head Bearing Adjustment
Refer to the applicable Service Manual for Springer Steering Head Bearing Adjustment procedures.
Headlamp
Refer the applicable Service Manual for Headlamp Assembly and Installation procedures.
Passing Lamps and Horn
Refer the applicable Service Manual for Passing Lamp and Horn Assembly and Installation procedures.
SERVICE PARTS
Figure 1. Spring and rigid Fork Components-Subassemblies Part Number 46177-00 and 46178-00
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
Spring and Rigid Fork Component Subassembly, Part Number 46177-00 | Spring and Rigid Fork Component Subassembly, Part Number 46178-00 | |||||
1 | Screw | 855B | 28 | Nut, acorn | 7959 | |
2 | Nut, acorn (4) | 7680W | 29 | Rubber washer | 6829 | |
3 | Lockwasher | 7232 | 30 | Bearing adjuster | 48306-88 | |
4 | Washer (6) (refer to Illust. 2 also) | 6812 | 31 | Clamp, upper triple | 45491-97 | |
5 | Washer, spring rod (2) | 6353 | 32 | Pinch bolt | 4350A | |
6 | Reflector, L.H. amber | 59290-92 | 33 | Screw | 3538 | |
7 | Reflector, R.H. amber (not shown) | 59289-92 | 34 | Cable tie (3) | 10065 | |
8 | Front shock absorber | 54482-97 | 35 | Dust shield | 48361-80 | |
9 | Label, shock | 54329-97 | 36 | Clamp, brake line | 10076 | |
10 | Retainer, spring, upper (2) | 46060-88 | 37 | Bearing, upper | 48345-60 | |
11 | Cups, rebound spring (2) | 46057-88 | 38 | Clip, throttle cable | 10190 | |
12 | Spring cup, compression spring (2) | 46056-88 | 39 | Cable tie (5) | 10006 | |
13 | Spring, compression-outer (2) | 46055-88 | Riser Components Subassembly, Part Number 46178-00 | |||
14 | Spring, compression-inner (4) | 46054-88 | 40 | Isolator, rubber (4) | 53157-97 | |
15 | Upper spring (2) | 46053-88 | 41 | Riser (2) | 56548-97 | |
16 | Spring seat (4) | 45937-88 | 42 | Washer (2) | 6756 | |
17 | Travel bumper (4) | 45936-88 | 43 | Locknut (2) | 7768W | |
18 | Bushing, spring rod (2) | 45935-88 | 44 | Ground spring | 46058-97 | |
19 | Front fork assembly | 45633-00 | 45 | Caps (2) | 56538-88 | |
20 | Spring, fork | 45619-97 | 46 | Cap screw (4) | 3494A | |
21 | Nut, acorn, lower spring rod (2) | 45567-88 | 47 | Bolt, riser stud (2) | 56550-97 | |
22 | Spring rod, lower (2) | 45566-88 | A | lower bearing | See note below | |
23 | Spring rod, upper (2) | 45543-88 | ||||
24 | Bolt | 4029A | ||||
25 | Screw | 3533 | ||||
26 | Label, spring bridge | 14192-88 | ||||
27 | Spring bridge | 46062-88 | ||||
Note: Item A, lower bearing shown installed | ||||||
Figure 2. Suspension Lower End Components-Subassembly Kit Part Number 46177-00
Table 2. Service Parts Table
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
48 | Ball, spherical bearing (4) | 9141 | 59 | Bearing retainer, rigid fork (2) | 45655-88 | |
49 | Race, spherical bearing (4) | 9140 | 60 | Fork rocker, left (caliper side) | 45631-97 | |
50 | Bearing, spherical (2) | 9139 | 61 | Fork rocker, right (not shown) | 45629-97 | |
51 | Nut (4) | 7880 | 62 | Assembly, bracket, brake reaction | 44236-97 | |
52 | Nut, acorn (2) | 7862 | 63 | Bearing race | 44086-97 | |
53 | Washer, thrust | 6042A | 64 | Pivot sleeve | 44031-97 | |
54 | Pivot stud, rigid fork to rocker (2) | 45684-90 | 65 | Screw | 4165 | |
55 | Washer (rocker to fork leg) (4) | 45662-88 | 66 | Screw | 4164 | |
56 | Pivot stud, spring fork to rocker (2) | 45683-90 | 67 | Bolt (2) | 4163 | |
57 | Jam nut, bearing retainer (2) | 45659-88 | 68 | Link, brake reaction | 41047-97 | |
58 | Bracket, fork leg | 45656-97 | 69 | Spacer, rubber | 11260 |
Figure 3. Headlamp, Passing Lamps and Horn Components Subassemblies Part Number 46177-00 and 46178-00
Table 3. Service Parts Table
Item | Description (Quantity) | Part Number | Item | Description (Quantity) | Part Number | |
|---|---|---|---|---|---|---|
Headlamp, Passing Lamps and Horn Component Subassembly, Part Number 46177-00 | Headlamp, Passing Lamps and Horn Component Subassembly, Part Number 46178-00 | |||||
70 | Nut, acorn (2) | 7892 | 85 | Headlight assembly | 67906-00 | |
71 | Nut (2) | 7624 | 86 | Washer (2) | 6379W | |
72 | Housing, 2-place socket | 73152-96WE | 87 | Screw (2) | 2917 | |
73 | Wire, horn ground (not shown) | 70410-97 | ||||
74 | Horn assembly w/mounting pad | 69070-97A | ||||
75 | Horn cover | 69069-97 | ||||
76 | Assembly, passing lamp (2) | 68758-97 | ||||
77 | Clamp block (2) | 68720-62 | ||||
78 | Bracket, headlight mounting | 67892-93 | ||||
79 | Bracket, passing lamp weldment | 58089-97 | ||||
80 | Bolt | 3214 | ||||
81 | Screw (3) | 2939 | ||||
82 | Screw (2) | 3638 | ||||
83 | Grommet (2) | 11410 | ||||
84 | Screw (2) | 2447 | ||||