1. | Place suitable blocking under frame to raise front wheel several inches off the floor. For best results, use a hydraulic center stand on a level surface. | |||||||||||
2. | See the service manual and remove front wheel, fender and brake caliper. | |||||||||||
3. | Spray glass cleaner on the fork tube between upper and lower fork bracket to lubricate. |
Figure 1. Loosen Pinch Bolt
Figure 2. Fork Tube Holder (HD-41177) | ||||||||||
4. | See Figure 1. While holding the fork slider to prevent the fork from dropping, loosen pinch screws (2). | |||||||||||
5. | Remove fork tube by sliding the fork tube down and out of the upper and lower fork brackets. | |||||||||||
6. | Repeat Steps 3-5 to remove opposite fork. | |||||||||||
7. | Move forks to bench area. Place suitable drain pan on floor beneath vise. |
1 | Fork tube cap |
2 | Fork tube holder |
3 | Vise |
1. | See Figure 8. Install new lower bushing (F) in groove of slider tube (E). Expand bushing only wide enough to fit over the tube. | |
2. | Place rebound spring (D) over damper tube. Verify that the damper tube ring (C) is installed in groove at top of new damper tube (2). Insert damper tube into slider tube (E). | |
3. | Insert new spring (1) into slider tube (E) with the dense coil end down. Push damper tube (2) through opening at the bottom of the tube using the spring. Place the lower stop (M) over the end of the damper tube. | |
4. | Install the slider tube assembly into the slider (N, O or P). | |
5. | Install the screw and washer (Q) into the bottom of the slider (N, O or P). Move the slider tube through its full range of travel within the slider several times to verify proper component alignment. Then, applying downward force on the spring and tighten the screw. Tighten screw to 15–25 N·m (11–18 ft-lbs). | |
6. | Place the upper bushing (L), spacer (K) (concave side down), oil seal (J) (lettering side up), and FORK SEAL AND BUSHING INSTALLATION TOOL (Part Number HD-36583) over slider. | |
7. | See Figure 5. Install bushing, spacer and seal into slider bore by tapping components downward with the installation tool. | |
8. | See Figure 8. Install internal circle clip (I) into groove in top of the slider bore. | |
9. | Install dust seal (H) and cover (G) at the top of the slider. | |
10. | Install drain screw (R) into the lower end of the slider. Tighten the screw to 8–11 N·m (72–96 in-lbs). | |
11. | Remove main spring (1) from slider tube (E). | |
12. | Pour 350 ml of Harley-Davidson Type E Fork Oil into fork tube. | |
13. | Pump fork tube 10 times to remove air from system. | Figure 4. Fork Seal/Bushing Tool (HD-34634) Figure 5. Install Fork Oil Seal |
![]() 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) | ||
14. | See Figure 7. Adjust the fork oil level, so that it is 120 mm (4.72 in) from the top of the fork tube with the fork tube compressed and the main spring removed. Proceed as follows: a. Loosen thumbscrew of FRONT FORK OIL LEVEL GAUGE (HD-59000B) on metal ring and move it up or down the rod until the bottom of the ring is 120 mm (4.72 in) from the bottom of the rod. Tighten thumbscrew. b. Push the handle on the cylinder all the way in. c. Insert rod into top of fork tube until metal ring rests flat on top of fork tube and the slider tube is pushed all the way into the slider. d. Pull out handle to remove fork oil from fork tube. Observe fork oil through transparent tube as it is drawn into cylinder. e. Remove rod from fork tube. Push handle into cylinder to eject excess fork oil into suitable container. f. If necessary, repeat Steps 14(b)-14(e). Level is correct when no fork oil is observed being drawn through transparent tube. | |
15. | Install main spring (1) into the slider tube (E) with the dense coil end down. | |
16. | Install spring washer (S) and then spring collar (T) (from original fork). | |
17. | Install slider tube cap (A) and O-ring (B) on top of slider tube. Tighten cap to 29.9–80 N·m (22–59 ft-lbs). | Figure 6. Front Fork Oil Level Gauge (HD-59000B) Figure 7. Remove Excess Fork Oil |
18. | Remove fork assembly from fork tube holder. | |
19. | Repeat Steps 1-18 for the opposite fork assembly. |
1. | See Figure 1. Insert fork slider through the front lower and upper brackets. Position slider tubes so that the top of each tube cap (1) extends 10.7–12.7 mm (0.42–0.5 in) above top surface of front fork upper bracket. | |
2. | On models with directional lamps mounted to the front fork bracket, hold directional lamp mounting brackets upright. On all models, tighten front fork upper and lower bracket pinch screws (2) to 40.7–47.5 N·m (30–35 ft-lbs). | |
3. | Repeat Steps 1 and 2 for opposite fork. | |
4. | See the service manual and install the front fender, wheel and brakes. | |
![]() 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) | ||
5. | Pump brake hand lever to build system pressure. | |
6. | Test ride the motorcycle to verify proper fork travel and rebound. If the brakes feel spongy, bleed the brake system again. |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | Spring (2) | Not Sold Separately |
2 | Damper tube (2) | Not Sold Separately |
Items mentioned in text, but not included in kit: | ||
A | Cap, slider tube (2) | |
B | O-ring (2) | |
C | Ring, damper tube (2) | |
D | Spring, rebound (2) | |
E | Slider tube with slider tube bushing (2) | |
F | Bushing, lower (2) | |
G | Cover, slider (2) | |
H | Seal, dust (2) | |
I | Circle clip (2) | |
J | Oil seal (2) | |
K | Spacer, oil seal (2) | |
L | Bushing, upper (2) | |
M | Lower stop (2) | |
N | Slider assembly, left | |
O | Slider assembly, right (all except XL883R/XL1200R) | |
P | Slider assembly, right (XL883R/XL1200R) | |
Q | Screw and washer (2) | |
R | Drain screw with washer (2) | |
S | Washer, spring (2) | |
T | Collar, spring (2) |