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CHROME/BLACK FORK SLIDER KIT
J064422025-10-03
GENERAL INFORMATION
Table 1. General Information
Kits
Suggested Tools
Skill Level(1)
45500399, 45500400, 45500401, 45500402, 45500406, 45500403, 45500404, 45500405
Safety glasses, Torque wrench
(1) Tightening to torque value or other moderate tools and techniques required
KIT CONTENTS
Figure 1. Kit Contents: Chrome/Black Fork Sliders
Table 2. Kit Contents: Chrome/Black Fork Sliders
Verify that all contents are present in the kit before installing or removing items from vehicle.
Item
Qty
Description
Part No.
From Kit
1
1
Fork slider, right (chrome)
45500408
45500410
45500412
45500414
45500423
45500399
45500400
45500401
45500402
45500406
1
Fork slider, right (black)
45500416
45500418
45500420
45500403
45500404
45500405
2
2
O-Ring
46508-01
All
3
2
49 mm Oil seal
46514-01A
4
1
Fork slider, left (chrome)
45500407
45500409
45500411
45500413
45500422
45500399
45500400
45500401
45500402
45500406
1
Fork slider, left (black)
45500415
45500417
45500419
45500403
45500404
45500405
5
2
Tape, double-sided foam
53791-06
All
6
2
Copper packing washer
46615-06
7
2
Bolt, Hex socket
46614-06
GENERAL
Instruction sheet is also available electronically. To verify you are using the most current version available, do one of the following:
  • Go to h-d.com/isheets
  • Scan QR code in upper left corner of the instruction sheet
NOTE
This instruction sheet may have a Supplemental Video to assist installer in clarifying a certain part of the assembly. A linked video would be located at the end of this instruction sheet.
Models
For model fitment information, see the Parts and Accessories (P&A) Retail Catalog or the Parts and Accessories section of www.harley-davidson.com.
Contact Harley-Davidson Customer Support Center at 1-800-258-2464 (U.S. only) or 1-414-343-4056.
Installation Requirements
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 the year and model motorcycle is required for this installation and is available from:
  • A Harley-Davidson dealer.
  • H-D Service Information Portal (SIP), a subscription-based access available for most 2001 and newer models.
Proper installation of this kit requires the following parts and supplies:
Proper installation of this kit also requires the following special tools:
PREPARE
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
NOTE
For vehicles equipped with security siren:
  • Verify that the hands-free fob is present. Turn ignition switch ON.
1. Remove main fuse. See owner's or service manual.
REMOVE
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)
1. Raise front end of vehicle. See service manual.
2. Remove front fender, front brake calipers and front wheel. See service manual.
NOTE
On some models, additional parts must also be removed to access front forks. See service manual.
3. Remove, drain and disassemble front forks. See service manual.
4. Clean and inspect all parts not being replaced for wear or damage. Replace items as necessary. See service manual.
5. For models with fork-mounted reflectors: Using a piece of dental floss (or similar material) in a back and forth motion, loosen top and bottom of reflector from fork slider. Rotate reflector from side to side until it can be removed. Save reflector for later assembly. Repeat for remaining reflector. Peel off any excess adhesive from both reflectors.
INSTALL
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)
The fork sliders included in these kits install in the same manner as original equipment parts. See service manual for proper installation procedures.
Pay close attention to all warnings, cautions and torque specifications when installing these fork sliders.
NOTE
Check bores of new sliders before installation. Dirt and debris can damage sliders.
1. Assemble front fork tubes per service manual instructions, with the following exceptions:
a. Replace original fork sliders with new chrome or black sliders (see Figure 1 , items 1 and 4).
b. Replace original slider oil seal on each side with a new slider oil seal (3).
c. Replace any other worn seals, bushings or other items as needed.
2. Fill front forks with Type "E" Hydraulic Fork Oil (Part No. 62600026). See service manual.
3. Install two new O-rings (2) on fork tube plugs.
4. Complete assembly of front fork tubes. See service manual.
5. Install front forks to vehicle. See service manual.
6. Install front wheel, front brake calipers, front fender and any additional items removed earlier. See service manual.
7. For models with fork-mounted reflectors:
a. Ambient temperature should be between 21–38 °C (70–100 °F) for proper adhesion. Do not apply double-sided foam tape below 10 °C (50 °F).
b. Parts cannot be repositioned after initial adhesive installation.
c. Allow at least 24 hours after application before exposing the area to vigorous washing, strong water spray or extreme weather.
d. The adhesive bond will increase to maximum strength after about 72 hours at normal room temperature.
e. Do not clean with denatured alcohol, mineral spirits or other solvents. Damage to components occurs.
8. Clean back of reflector with a mixture of 50 percent isopropyl alcohol and 50 percent distilled water. Allow to dry completely.
9. Peel liner from one side of double-sided foam tape (see Figure 1 , item 5). Position tape to back of reflector. Press firmly into place. Repeat for remaining reflector.
10. Clean reflector mounting area of fork slider with a mixture of 50 percent isopropyl alcohol and 50 percent distilled water. Allow to dry completely.
NOTE
Per regulations: Reflector to be placed on center line perpendicular to side view.
11. See Figure 2. Peel remaining liner from tape. Place reflector in position on fork slider. Locate bottom edge of reflector 58.67 mm (2.31-in) above the center of axle shaft as shown. Press firmly into place. Hold reflector in position with steady pressure for approximately one minute. Repeat for remaining reflector.
1Install bottom of reflector 2.31-inches (58.67 mm) above center of axle
Figure 2. Reflector Placement
COMPLETE
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)
WARNING
After repairing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a)
NOTE
Verify ignition switch is in OFF position before installing the main fuse or attaching the negative battery cable.
1. Install main fuse. See owner's manual or service manual.
2. Pump brakes before test riding vehicle.
3. Test ride vehicle to verify proper fork travel and rebound.