SCREAMIN EAGLE ADJUSTABLE FRONT FORK KIT
J064272016-08-22
GENERAL
Kit Number
45400176
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Installation Requirements
  • Proper installation of this kit also requires the following special tools:
  • Loctite® 565 Thread Sealant (99818-97)
  • Harley-Davidson® Type E Fork Oil (62600026)
  • Harley-Davidson Seal Grease (11300005)
  • Fork Tube Holder (HD-41177)
  • Fork Seal/Bushing Tool (HD-36583)
  • Front Fork Oil Level Gauge (HD-59000B)
  • Front Fork Spring Compressing Tool (HD-45966)
  • Extension tool (HD-45966-1)
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 your model motorcycle is required for this installation. One is available from a Harley-Davidson Dealer.
Kit Contents
See Figure 9 and Table 4.
REMOVAL
  1. See service manual. Remove front fender, wheel and brakes.
  2. See service manual. Remove front forks.
LEFT AND RIGHT FORK DISASSEMBLY
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)
NOTE
Be aware fork bolt is under spring pressure, make sure to have a firm grasp on the bolt as the last thread is turned.
  1. See service manual for fork disassembly. Instructions vary by model and year.
  2. NOTE
    Inspect parts for wear or damage. Replace or repair as necessary.
  3. Retain these stock parts to use with new fork kit:
    1. Dust covers
    2. Fork boots (if equipped)
    3. Stopper rings
    4. Seal spacers
    5. Bushings
    6. Fork sliders
  4. Discard remaining parts.
FORK ASSEMBLY
NOTE
Refer to Figure 9 for the following procedure unless the step says otherwise.
NOTICE
Exercise caution to avoid scratching or nicking fork tube. Damaging tube can result in fork oil leaks after assembly. (00421b)
NOTE
Harley-Davidson recommends that kit contents be separated between the right side and left side before beginning procedure. To visually differentiate between right and left damper:
  • The right damper can be identified by holes near the top of the cartridge.
  • The left damper can be identified by holes near the bottom of the cartridge.
It is imperative that the correct parts are installed in the proper fork assembly. Always build one complete fork assembly before repeating the procedure for the opposite side.
1.
Unless already installed, coat new fork slide bushing (11) ID with clean fork oil. Expand fork slide bushing at split line only as far as required to slip over end and into groove of fork tube (6).
2.
Install fork slider (F or K) in fork tube holder. Slide fork tube (6) into fork slider.
3.
Coat inner diameter (ID) and outer diameter (OD) of guide bushing (E) with clean fork oil. Slide guide bushing down fork tube (6) (either direction).
4.
Slide seal spacer (D) down fork tube until it contacts guide bushing (either direction).
5.
Coat the ID of the new fork oil seal (2) with clean fork oil. Coat the OD of the fork oil seal with Harley-Davidson Seal Grease. With the lettering side facing up, slide fork oil seal down the fork tube until it contacts the seal spacer.
6.
See Figure 1. Obtain the Fork Seal/Bushing Tool (HD-36583) and proceed:
a.
Slide the fork seal installer down the fork tube until it contacts the fork oil seal.
b.
Using the tool like a slide hammer, drive fork oil seal (with seal spacer and guide bushing) down the fork tube until stopper ring groove is visible in fork slider ID.
c.
Slide the stopper ring (C) down the fork tube until it contacts the fork oil seal. Install stopper ring in the fork slider groove. Do not expand or stretch stopper ring to install on fork tube or ring could be damaged.
Figure 1. Install Fork Oil Seal
7.
Install dust seal (1).
8.
Remove assembly from fork tube holder.
NOTE
Left damper can be identified by holes near the bottom of the cartridge. Right damper can be identified by holes near the top of the cartridge.
9.
See Figure 6. Remove fork bolt (3) from damper rod (4) by loosening jamnut (5). The jamnut is to remain on damper rod.
10.
Set fork bolt (w/needle rod) aside.
11.
Install oil lock (8) over the end of the damper cartridge (7 or 10).
12.
Hold fork assembly horizontal and slide damper cartridge with oil lock into fork assembly.
13.
Push down on cartridge.
14.
Apply Loctite 565 Thread Sealant to screw (9). Install new screw (9) with copper crush washer. Slide screw through hole at bottom of fork slider and start into end of damper cartridge.
15.
Obtain fork spring (5) from the kit. Install new fork spring into fork tube.
16.
Put a shop rag on the floor. Turn the fork assembly upside down. Press the end of the spring against the rag. Compress the spring and tighten the screw (9) to 20 ± 5 N·m (15 ± 4 ft-lbs).
17.
With the fork tube upright, clamp fork slider (not the fork tube) into fork tube holder.
18.
Fill the fork tube:
a.
See Figure 2. Thread extension tool onto end of damper rod.
b.
With the fork tube compressed, pour Harley-Davidson Type E Fork Oil into the fork tube almost to the top. Pump fork tube ten times to remove air from system.
c.
Slowly pump the damper rod until resistance is felt through the entire stroke. Then pump ten more times.
d.
Place the damper rod in the fully bottomed position. Verify that fork pipe is bottomed out.
Figure 2. Pump Damper Rod Extension Tool
WARNING
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)
19.
See Figure 3. Adjust the fork oil level, so that it is 170 mm (6.69 in) from the top of the fork tube with the fork tube compressed and the fork spring removed.
a.
Obtain the Front Fork Oil Level Gauge (HD-59000B).
b.
Loosen thumbscrew on metal ring and move it up or down the rod until the bottom of the ring is 170 mm (6.69 in) from the bottom of the rod. Tighten thumbscrew.
c.
Push the plunger on the cylinder all the way in.
d.
Insert rod into top of fork tube until metal ring rests flat on top of fork tube.
e.
Pull plunger to remove fork oil from fork tube. Observe fork oil through transparent tube to verify that oil is being drawn from fork.
f.
Remove rod from fork tube. Push plunger into cylinder to eject excess fork oil into suitable container.
g.
If necessary, repeat Steps 19(c) through 19(f). Level is correct when no fork oil is observed being drawn through transparent tube.
NOTE
Verify that the fork spring is installed with dense section of coils to the bottom.
Figure 3. Remove Excess Fork Oil
20.
Install fork spring into the fork tube (6) with the dense end down.
21.
Confirm that the jamnut is on the damper rod.
NOTE
Do not use an air impact wrench to adjust the fork spring compression tool.
WARNING
Wear safety glasses or goggles when removing or installing spring. Spring tension can cause spring, attached components and/or hand tools to fly out which could result in death or serious injury. (00477c)
22.
See Figure 4. Install fork spring compressing tool:
a.
Clamp tool in vise in a vertical position with length adjustment screw (2) upward.
b.
Place hole at bottom of fork slider over post (4) at bottom end of tool.
c.
See Figure 9. Place spring joint (3) , spring collar (4), and spring joint (3) over the damper rod extension tool and on top of spring.
d.
See Figure 5. Adjust tool as necessary until two retaining pins engage through holes in spring collar (1). Turn length adjustment screw counterclockwise to lengthen and clockwise to shorten.
e.
Turn retaining pins as necessary to lock position of spring collar.
f.
Turn length adjustment screw clockwise to compress spring.
1Damper rod extension tool
2Length adjustment screw
3Retaining pin (3)
4Post
Figure 4. Fork Spring Compressor Tool (HD-45966)
1Spring collar
Figure 5. Compress Fork Spring
23.
After a number of turns, pull up on extension tool to raise damper rod. If threaded portion of rod cannot be pulled out of spring collar, compress spring further. Repeat until threaded portion of rod can be pulled out of spring collar.
24.
Remove extension tool, while holding the damper rod in the extended position.
25.
See Figure 6. Install and assemble fork bolt.
a.
Bottom out the jamnut (5) on the damper rod (4).
b.
Make sure that the damping force adjustment knob (2) is bottomed out on fork bolt before install.
c.
Confirm that O-ring is installed on fork bolt.
d.
Install fork bolt (3) with needle rod into the damper rod (4) slowly. Hand tighten the fork bolt to the damper rod until fork bolt is bottomed out on the damper rod.
e.
Turn jamnut (5) until it makes firm contact with fork bolt (3). Tighten and torque jamnut (14 mm) to fork bolt (17 mm). 20 ± 2.5 N·m (15 ± 1.8 ft-lbs)
f.
Tighten fork bolt (1)(35 mm natural color) to fork bolt (3)(17 mm orange color). 35 ± 5 N·m (26 ± 3.7 ft-lbs)
1Fork bolt (35 mm natural color)
2Damping force adjustment knob
3Fork bolt (17 mm orange color)
4Damper rod
5Jamnut (14 mm)
Figure 6. Fork Bolt Assembly
26.
Release tension on compression tool and remove fork assembly.
27.
Make sure that spring, washers and spring collar are all aligned. Push to center with fingers if necessary.
28.
Install fork tube holder in vise. Clamp fork tube into fork tube holder.
NOTE
Do NOT over-tighten. O-ring damage can occur.
29.
Install new fork bolt into fork tube (6). Tighten fork bolt to 55 ± 25 N·m (40.5 ± 18.5 ft-lbs).
30.
Install duct cover (A) or fork boot (B, if equipped).
31.
Repeat procedure for other fork assembly.
Fork Installation
1.
See service manual. Install front forks.
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)
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)
2.
See service manual. Install front fender, wheel, brakes and any other removed parts.
3.
Pump brakes to build system pressure.
4.
See fork adjustment section to set preload and damping for your riding style and road conditions.
Fork Adjustment
Fork Preload Adjustment
The front and rear preload setting will need to be adjusted for the rider's weight and cargo. This adjustment should be made before the motorcycle is ridden any distance and after changing the overall vehicle weight (adding saddlebags, etc.). Changes in the load carried requires changes in the preload settings. Carrying less weight than was used for setting up the suspension requires decreasing the amount of preload. Increasing the load carried requires adding more preload.
WARNING
Adjust both forks equally. Improper fork adjustment can lead to loss of control, which could result in death or serious injury. (00124c)
  1. See Table 1. Determine preload setting for your riding weight with gear.
  2. See Figure 7. Turn preload hex (1) counterclockwise till it stops.
  3. Adjust preload hex to desired location determined in step 1.
  4. Repeat steps 1 through 3 on opposite side.
Fork Preload Table
1Preload hex adjustment
2Number of rings
Figure 7. Fork Preload Adjustment
Table 1. Suspension Preload Table
RIDER WEIGHT
PRELOAD SETTING (mm)
NUMBER OF VISIBLE RINGS
0-135 lbs
0-61 kg
0
7
135-143 lbs
61-65 kg
1
143-151 lbs
65-68 kg
2
6
151-159 lbs
68-72 kg
3
159-167 lbs
72-76 kg
4
5
167-175 lbs
76-79 kg
5
175-182 lbs
79-93 kg
6
4
182-190 lbs
83-86 kg
7
190-198 lbs
86-90 kg
8
3
198-206 lbs
90-94 kg
9
206-214 lbs
94-97 kg
10
2
214-222 lbs
97-101 kg
11
222-230 lbs
101-104 kg
12
1
230-238 lbs
104-108 kg
13
238-241 lbs
108-109 kg
13.4
0
Fork Damping Adjustment
NOTICE
Compression and rebound adjusting valves may be damaged if too much force is used at either end of the adjustment range. (00237a)
NOTE
See Table 2 for rebound (TEN) and compression (COMP) damping adjustment.
Fork Rebound Damping Adjustment
  1. See Figure 8. Turn rebound damping adjuster clockwise until it stops. This is the maximum rebound damping setting.
  2. Turn adjuster counterclockwise to the desired setting.
Fork Compression Damping Adjustment
  1. See Figure 8. Turn compression damping adjuster clockwise until it stops. This is the maximum compression damping setting.
  2. Turn adjuster counterclockwise to the desired setting.
1Rebound (TEN)
2Compression (COMP)
Figure 8. Fork Damping Adjustments
Table 2. Recommended Fork Rebound and Compression Damping Adjustment
DAMPING
NOMINAL (From Maximum)
Compression (COMP)
7 clicks
Rebound (TEN)
7 clicks
Values shown are counterclockwise turns from maximum. Rotate adjuster clockwise to increase damping or counterclockwise to decrease damping.
Suspension Tuning
After the preload and damping have been set to the recommended settings, additional adjustments can be made to enhance the comfort, control and handling characteristics of the motorcycle.These adjustments may be based on personal riding style, desired ride quality and varying road conditions.
  1. Set the front forks and shock absorbers to the recommended settings. Properly inflate the tires.
  2. Determine the ride quality of the motorcycle. Ride the motorcycle on a familiar road with various bumps and turns. Ride over different surfaces at varying speeds. If the suspension is set properly, the vehicle suspension will feel controlled and comfortable.
  3. See Table 3. Adjust the rebound and compression damping according to the motorcycle behavior experienced during the ride.
  4. After adjusting the suspension, ride the motorcycle again to check for comfort and response.
  5. NOTE
    When tuning the suspension, make all adjustments in small increments. Radical setting changes may overshoot the best adjustment setting.
Table 3. Suspension Damping Adjustment Guidelines
MOTORCYCLE BEHAVIOR
SUGGESTED REMEDY
Soft or unsettled feeling around corners or after bumps
Increase rebound damping
Leaping feeling or topping after large bumps
Increase rebound damping
Harsh/sharp feedback over bumps
Decrease rebound damping
Feels like motorcycle drops down over chatter bumps
Decrease rebound damping
Excessive bottoming through potholes
Increase compression damping
Excessive dive when applying front brake
Increase compression damping (forks)
Hard feeling or inadequate absorption over bumps
Decrease compression damping
Feels excessively stiff or busy around corners
Decrease compression damping
NOTE:
Behavior felt through the handlebars should be remedied with front fork damping changes.
Behavior felt through the seat should be remedied with rear shock damping changes.
SERVICE PARTS
Figure 9. Service Parts: XL Standard Cartridge Front Fork Kit
Service Parts Table
Table 4. Service Parts Table
Item
Description (Quantity)
Part Number
Items included in kit:
1
Dust seal (2)
45401-87
2
Oil seal (2)
45378-87
3
Spring joint (4)
46262-02
4
Spring collar (2)
45500285
5
Spring (2)
48738-07
6
Fork tube (with slide bushing, item 11)(2)
45500276
7
Damper cartridge, right (Compression damping adjustment)
45500283
8
Oil lock (2)
45378-87
9
Bolt with washer (2)
45500286
10
Damper cartridge, left (Rebound damping adjustment)
45500299
11
Slide bushing
45465-87
Items mentioned in text, but not included in kit:
A
Dust cover (2)
B
Fork boot (2)
C
Stopper ring (2)
D
Seal spacer (2)
E
Guide bushing (2)
F
Fork slider, right
G
Nut
H
Lockwasher
I
Washer
J
Pinch bolt
K
Fork slider, left