CHROME FORK SLIDERS
J042652006-08-30
GENERAL
Kit Number
48661-07
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
Harley-Davidson TYPE E FORK OIL (Part Number HD-99884-80, 16 oz./0.47 L) will be required.
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.
Tools Required
- Air impact wrench
- Torque wrench
- Fork spring compression tool
- Damper tube extension tool
- Fork Tube Holder HD-41177
- Front Fork Oil Level Gauge HD-59000-A
- Fork Seal and Bushing Tool HD-34634
INSTALLATION
The chrome fork sliders included in this kit install in the same manner as the original equipment parts. Refer to the Service Manual for proper installation procedures.
Pay close attention to all warnings, cautions, and torque specifications when installing these fork sliders.
NOTE
Prior to installation of this kit, check the bores of the new chrome sliders to be certain they are free of dirt and debris or damage to the new sliders may occur.
| 1. | Support the motorcycle so the front end is off the floor and the forks are fully extended. | |||||||||||
| 2. | Remove the front fender, front brake caliper, and front wheel according to the instructions found in the CHASSIS section of the Service Manual. Drain and remove the front forks per the instructions in the Service Manual CHASSIS section. NOTE On some models other parts will also need to be removed to access the front forks. See the Service Manual. | |||||||||||
| 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) | ||||||||||||
| 3. | Disassemble the front fork tubes according to instructions in the Service Manual, and replace the original fork sliders with the chrome sliders (see Figure 3 , items 1 and 2) from the kit. | |||||||||||
| 4. | Assemble the front fork tubes, replacing worn seals, bushings or other additional items as needed. Two new slider oil seals (7) are included in the kit. NOTE Do not use an impact wrench to tighten the drain screws. Use of an impact wrench may damage the screws. | |||||||||||
| 5. | Tighten the drain screws to 5.8–8.8 N·m (52–78 in-lbs). | |||||||||||
| 6. | Fill with TYPE E FORK OIL (Harley-Davidson part number 99884-80) according to the instructions found in the Service Manual. | |||||||||||
| 7. | See Figure 1. Retrieve one chrome sleeve (1) from the kit. With the machined step (2) pointing down, slide the sleeve down the fork tube (4) until it contacts the fork slider assembly (5). | |||||||||||
| 8. | Position the sleeve so that the drain hole (3) will face the rear of the vehicle when the fork is installed. Using the FORK BUSHING AND SEAL INSTALLER (Part No. HD-34634), drive the sleeve into the top end of the fork slider until the sleeve bottoms out against the top lip of the slider. | |||||||||||
| 9. | Install the front fork and any parts that were removed to access the front forks. Install the front fender, wheel, and caliper according to the instructions found in the CHASSIS section of the Service Manual. NOTE The front reflectors located on both sides of the original fork sliders must be removed, cleaned and installed on the new chrome fork sliders. Ambient temperature should be at least 60° F (16° C) for proper adhesion of the reflectors to the sliders. | 
Figure 1. Sleeve Installation | ||||||||||
| WARNING Federal Motor Vehicle Safety Standard (FMVSS) 108 requires motorcycles to be equipped with rear and side reflectors. Be sure rear and side reflectors are properly mounted. Poor visibility of rider to other motorists can result in death or serious injury. (00336b) | ||||||||||||
| 10. | Using a piece of dental floss (or similar material) in a back and forth motion, loosen the reflector ( Figure 3 , A) from the fork slider at both ends. Rotate the reflector from side to side until it can be removed from the fork slider. Retain the reflector for installation to the new slider. Repeat the procedure on the opposite side fork slider. | |||||||||||
| 11. | Peel off any excess adhesive from both reflectors. NOTE The bottom edge of the reflector should be two inches (50 mm) above the center of the axle shaft. | 
Figure 2. Reflector Placement | ||||||||||
| 12. | Peel the liner from one side of the foam double-sided tape. Position the tape to the back of the reflector, and press firmly into place. Peel the remaining liner from the tape. Place the reflector in position on the fork slider as shown in Figure 2 , and press firmly into place. Repeat the procedure on the opposite side fork slider. NOTE Allow AT LEAST 24 hours after applying the reflectors before exposing the area to vigorous washing, strong water spray or extreme weather. | |||||||||||
| WARNING Whenever 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) | ||||||||||||
| 13. | Pump the brakes prior to test riding the motorcycle. Test ride the vehicle to ensure proper fork travel and rebound. |
SERVICE PARTS
Figure 3. Service Parts: Chrome Fork Sliders
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Fork slider, left side (41 mm, chrome) | 48731-07 |
2 | Fork slider, right side (41 mm, chrome) | 48730-07 |
3 | Screw, drain (2) | 45369-99 |
4 | Washer, drain screw (2) | 45692-99 |
5 | Axle cap, right side (chrome) | 46499-00 |
6 | Axle retainer nut kit (chrome) | 45813-03 |
7 | Oil seal, slider (2) | 45875-84A |
8 | Fork cover (chrome sleeve) (2) | 48754-07 |
9 | Foam tape, double-sided (2) (not shown) | 53791-06 |
Items mentioned in text, but not included in kit: | ||
A | Reflector, front fork (2) | 60253-07 |