CHROME LOWER FORK SLIDERS
941005902025-01-25
GENERAL INFORMATION
Table 1. General Information
Kits | Suggested Tools | Skill Level(1) |
|---|---|---|
45800161 | Safety glasses, Torque wrench, Isopropyl alcohol |  |
(1) Tightening to torque value or other moderate tools and techniques required
KIT CONTENTS
Figure 1. Kit Contents: Chrome Lower Fork Sliders
Table 2. Kit Contents: Chrome Lower Fork Sliders
 | Verify that all contents are present in the kit before installing or removing items from vehicle. | ||||
|---|---|---|---|---|---|
Item | Qty | Description | Part No. | Notes | |
 | 1 | 2 | O-ring | 46508-01 | |
| 2 | 1 | Chrome Fork Slider Cover Kit | 45600022 | |
| 3 | 2 | Fork Seal | 46514-01A | |
| 4 | 2 | Double Sided Tape | 53791-06 | |
| 5 | 1 | Chrome Fork Slider, RH | not sold separately | |
| 6 | 1 | Chrome Fork Slider, LH | not sold separately | |
| 7 | 1 | Chrome Axle Cover Kit | 43000315 | |
| 8 | 2 | Copper Seal Washer | 46615-06 | |
| 9 | 2 | Screw, Damper | 45500118 | |
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
Proper installation of this kit requires the following parts and supplies:
- Loctite® 243 Medium Strength Threadlocker and Sealant - Blue (Part Number 99642-97)
- Either Permatex® ANTI-SEIZE LUBRICANT (Part Number 98960-97) or Loctite SILVER GRADE ANTI-SEIZE LUBRICANT (Part Number 11100001).
- Type "E" Hydraulic Fork Oil (Part Number 99884-80)
Proper installation of this kit also requires the following special tools:
- FORK HOLDING TOOL (Part Number HD-41177)
- FORK SEAL/BUSHING DRIVER (Part Number HD-45305)
- FRONT FORK OIL LEVEL GAUGE (Part Number HD-59000B)
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 the year and model motorcycle is required for this installation and is available from:
- A Harley-Davidson dealer.
- H-D Service Information Portal, a subscription-based access available for most 2001 and newer models. For more information see Frequently ask questions about subscriptions.
PREPARE
| 1. | Raise front wheel. See service manual. | |
| 2. | Remove nacelle or media tray and dash panel. See service manual. | |
| 3. | Remove front fender. See service manual. | |
| 4. | Detach front brake calipers and secure out of the way. See service manual. | |
| 5. | Remove front wheel. See service manual. |
REMOVE
| 1. | Remove left and right front fork assemblies. See service manual. | |
| 2. | Disassemble front fork assemblies. See service manual. | |
| 3. | Remove fork covers from lower fork clamp. See service manual. | |
| 4. | 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. |
ASSEMBLE
| 1. | Assemble forks with all NEW components from kit. See Service Manual. | |||
| 2. | For models with fork-mounted reflectors: a. Ambient temperature should be at least 16 °C (60 °F) for proper adhesion of the reflectors to the fork sliders. b. Allow at least 24 hours after applying the reflectors before exposing the area to vigorous washing, strong water spray or extreme weather. c. The adhesive bond will increase to maximum strength after about 72 hours at normal room temperature. | |||
| 3. | Clean reflector mounting area of fork slider with a 50:50 mixture of isopropyl alcohol and distilled water. Allow to dry completely. | |||
| 4. | See Figure 1 and Figure 2 . Peel liner from tape (4). Install reflector in position on fork as shown. Press firmly into place. a. Hold reflector in position with steady pressure for approximately one minute. | |||
| 5. | Repeat procedure on opposite side. | 
Figure 2. Reflector Placement |
INSTALL
| 1. | Install new fork covers onto lower fork bracket. See service manual. | |
| 2. | Install left and right fork assemblies. See service manual. |
COMPLETE
| 1. | Install front wheel. See service manual. | |
| 2. | Install front brake calipers. See service manual. | |
| 3. | Install front fender. See service manual. | |
| 4. | Install nacelle or media tray and dash panel. See service manual. | |
| 5. | Lower front wheel. See service manual. | |
| 6. | Verify proper operation of front and rear brake systems and front suspension. |