BLACK FORK SLIDER KIT
J049122010-04-08
GENERAL
Kit Number
48645-09
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 and Tools 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
When installing on MY07 vehicles you will need to purchase two 4042 screws and two 7062 washers.
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. We recommend that this kit be installed by a factory-trained technician at your Harley-Davidson dealership. Improper installation of this kit could result in death or serious injury.
- 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 (large diameter)
- Harley-Davidson Type E Fork Oil (HD-99884-80, 16 oz.).
- Loctite® 243 Threadlocker and Sealant - Blue (99642-97)
- Loctite® Anti-Seize Lubricant (98960-97)
WARNINGHarley-Davidson parts and accessories are designed for Harley-Davidson motorcycles. Using non-Harley-Davidson parts or accessories can adversely affect performance, stability or handling, which could result in death or serious injury. (00001b)
NOTE
The following items are not included in this kit, but may also be needed to complete the installation: slider bushing (2), slider tube bushing (2), damper tube wear ring (2), slider tube plug O-ring (2) (see Figure 2 ). These items should be replaced if found to be worn or damaged, and are available from any Harley-Davidson dealer. See the Harley-Davidson Parts Catalog for your year and model motorcycle to obtain the correct part numbers.
INSTALLATION
The fork sliders included in this kit install in the same way as the original equipment parts.
NOTE
Prior to installation of this kit, check the bores of the new 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(s), and front wheel according to instructions found in the Chassis section of the appropriate service manual. NOTE On some models other parts will also need to be removed to access the front forks. See the service manual. | |||
| 3. | Drain and remove the front forks. See the Chassis Section of 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) | ||||
| 4. | Disassemble the front fork tubes according to instructions in the service manual, and replace the original fork sliders with the black sliders from the kit. | |||
| 5. | Assemble the front fork tubes, replacing worn seals, bushings or other additional items as needed. NOTE Do not use an impact wrench to tighten the drain screws. Use of an impact wrench may damage the screws. | |||
| 6. | Tighten the drain screws to 5.9–8.8 N·m (52–78 in-lbs) | |||
| 7. | Fill with Harley-Davidson TYPE E FORK OIL according to the instructions found in the service manual. | |||
| 8. | Install the front fork and any parts that were removed to access the front forks. Install the front fender, wheel, and caliper(s) according to the instructions found in the Chassis section of the service manual. NOTE The front reflectors located on both sides of the replaced fork sliders will be removed, cleaned and installed on the new gloss black fork sliders. | 
Figure 1. Reflector Placement | ||
| 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) | ||||
| 9. | See Figure 1. Using a piece of dental floss (or similar material) in a back and forth motion, loosen reflector from fork slider at both ends. Rotate reflector from side to side until it can be removed. Retain reflector for future use. See Figure 2. Repeat procedure on the opposite side fork slider. | |||
| 10. | Peel off any excess adhesive from both reflectors. Surface must be clean for reinstallation. | |||
| 11. | Peel off one side of backing on foam double sided tape. Press firmly on tape to secure it to reflector. Repeat double sided adhesive tape installation on remaining reflector. NOTE The bottom edge of reflector should be two inches (50 mm) above the center of the axle shaft. | |||
| 12. | See Figure 1. Remove second side (outside surface) of adhesive backing. Place reflector in position (1) and press reflector firmly into place to activate the adhesive. Repeat for remaining reflector. | |||
| 13. | Pump brakes prior to test riding vehicle. | |||
| 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) | ||||
| 14. | Test ride the vehicle to verify proper fork travel and rebound. |
SERVICE PARTS
Figure 2. Service Parts: Black Fork Slider Kit
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Oil seal (2) | 45875-84A |
2 | Packing oil seal (2) | 45733-48 |
3 | Front fork slider, right, black | 48654-09 |
4 | Front fork slider, left, black | 48653-09 |
5 | Tape, double sided foam (2) | 53791-06 |
6 | Drain screw with washer (2) | 45858-77 |
7 | Axle holder, right, black | 48655-09 |