SOFTAIL (DLC) STANDARD FORK TUBE KIT

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GENERAL INFORMATION

Table 1. General Information

Kits	Suggested Tools	Skill Level⁽¹⁾
45500921	Safety Glasses, Torque Wrench

(1) Special tools or techniques required for installation

KIT CONTENTS

Figure 1. Kit Contents: Softail (DLC) Standard Fork Tube Kit

Table 2. Kit Contents: Softail (DLC) Standard Fork Tube Kit

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	2	Dust Seal, Fork	46512-01A
3	2	Oil Seal, Fork	46514-01A
4	2	Fork Tube Assembly	45500924
5	2	Seal Washer, Damper	46615-06
6	2	Screw, Damper	45500118

GENERAL

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.

Verify that the most current version of the instruction sheet is used. It is available at: h-d.com/isheets

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)

Proper installation of this kit also requires the following:

Loctite^® 565 Thread Sealant (99818-97)

Harley-Davidson^® Seal Grease (11300005)

Fork Tube Holder (HD-41177)

Fork Seal/Bushing Tool (HD-45305)

Front Fork Oil Level Gauge (HD-59000B)

Type E Fork Oil (62600026)

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.

NOTE

Important Cosmetic Information:

These DLC (Diamond-like Carbon Coating) fork tubes may show a variation in color (green, purple, etc.) in specific areas on the tube. Note: These areas will not be visible once installed. This variation in color has no impact on performance or coating longevity, it is simply cosmetic.
Due to the contrast of the DLC fork tube finish, fork oil residue will be more visible than previously seen on the chrome tube. This oil residue is normal and is not a symptom of a component failure.
A visual inspection of the fork tube upper chamfer will denote a minor black paint mark. This is part of the manufacturing process and is a normal appearance.

PREPARE

1.	Remove windshield (if equipped). See service manual.
2.	Remove front wheel. See service manual.
3.	Remove front fender. See service manual.
4.	Remove front brake calipers. See service manual.

REMOVE

Remove left and right fork assemblies. See service manual.

DISASSEMBLE

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)

Disassemble left and right fork assemblies. See service manual.

ASSEMBLE

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)

1.	Figure 1 Assemble left fork using new items from kit. See service manual.
2.	Complete assembly of left fork. See service manual.
3.	Assemble right fork using new items. See service manual.
4.	Complete assembly of right fork. See service manual.

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)

INSTALL

Install left and right fork assemblies. See service manual.

COMPLETE

1.	Install front fender. See service manual.
2.	Install front wheel. See service manual.
3.	Install front brake calipers. See service manual. a. Pump brakes to build system pressure.
4.	Install windshield (if equipped). See service manual.

Test Ride

1.	Test ride motorcycle to verify fork travel and rebound.
2.	Verify brake system and forks are not leaking fluid.