1. | See Figure 6 . Obtain new damper tube (2) from kit and install rebound spring (F) over the lower end. | |
2. | With the wear ring topside, slide new damper tube into fork tube, so that tube end drops through hole at bottom of fork tube (G). Install lower stop (L) on the lower end of damper tube. | |
3. | Install fork slider (O or N) in fork tube holder. Slide fork tube into fork slider. | |
4. | If necessary, obtain new slider bushing (K) (45940-84, not included). Coat slider bushing ID with clean fork oil. Slide slider bushing (K) down fork tube. | |
5. | Slide slider spacer (J) down fork tube until it contacts slider bushing. | |
6. | Obtain new fork oil seal (I) (45875-84A, not included). Coat fork oil seal ID with clean fork oil. With the lip garter spring side facing down (toward the fork slider), slide oil seal down fork tube until it contacts slider spacer (J). Remove masking tape from edge of fork tube. | Figure 2. Fork Seal/Bushing Tool (HD-34634) Figure 3. Install Fork Oil Seal |
7. | See Figure 2. Obtain the FORK OIL SEAL INSTALLER (HD-34634) and proceed as follows: a. Slide the fork seal installer down the fork tube until it contacts the fork oil seal. b. See Figure 3. Using the tool like a slide hammer, drive fork oil seal (with slider spacer and guide bushing) down the fork tube until retaining clip groove is visible in fork slider ID. c. Slide the retaining clip (H) down the fork tube until it contacts the fork oil seal. Install retaining clip in the fork slider groove. Do not expand or stretch retaining clip to install on fork tube or clip may become bent or distorted. NOTE Make sure the fork spring is installed with dense section of coils to the bottom. | |
8. | Obtain new fork spring (1) from kit. Install new fork spring into fork tube. | |
9. | Remove fork assembly from fork tube holder. | |
10. | Place a shop rag on the floor, and turning fork assembly upside down, press end of spring against rag. | |
11. | Install new screw with copper crush washer (45405-75A, not included). Slide screw through hole at bottom of fork slider and start into end of damper tube. | |
12. | While compressing spring to prevent rotation of damper tube, tighten the screw to 15–24 N·m (11–18 ft-lbs). | |
13. | Remove fork spring from fork tube. | |
14. | With the fork tube topside, clamp fork slider (not the fork tube) into fork tube holder. NOTE Install the drain screw at the bottom of the fork slider, if removed. Tighten the screw to 8–11 N·m (72–96 in-lbs). | |
15. | Pour 350 ml of Harley-Davidson Type E Fork Oil into fork tube. | |
16. | Pump fork tube 10 times to remove air from system. | Figure 4. Front Fork Oil Level Gauge (HD-59000B) Figure 5. Remove Excess Fork Oil |
17. | Adjust the fork oil level, so that it is 4.88 inches (124 mm) from the top of the fork tube with the fork tube compressed, the main spring removed and the blow valve installed. Proceed as follows: a. See Figure 4. Obtain the FRONT FORK OIL LEVEL GAUGE (Part Number HD-59000B). b. Loosen thumbscrew on metal ring and move it up or down the rod until the bottom of the ring is 4.88 inches (124 mm) from the bottom of the rod. Tighten thumbscrew. c. Push the handle on the cylinder all the way in. d. See Figure 5. Insert rod into top of fork tube until metal ring rests flat on top of fork tube. e. Pull out handle to suck fork oil from fork tube. Observe fork oil through transparent tube as it is drawn into cylinder. f. Remove rod from fork tube. Push handle into cylinder to eject excess fork oil into suitable container. g. If necessary, repeat Steps 17(c) through 17(f). Level is correct when no fork oil is observed being drawn through transparent tube. | |
18. | Install fork spring into the fork tube with the dense end down. NOTE Do NOT overtighten or O-ring damage may occur. | |
19. | Install new O-ring (45845-77, not included) onto fork tube plug (B). Compressing fork spring with end of fork tube plug, thread fork tube plug into fork tube. Tighten fork tube plug to 30–79 N·m (22–59 ft-lbs). | |
20. | Install new quad ring seal (D) (45733-48, not included) onto fork cap bolt. Thread fork cap bolt (A) into fork tube plug to prevent loss of fork oil while handling. | |
21. | Loosely install axle holder, flat washers, lockwashers and nuts on studs at end of fork slider. | |
22. | Repeat steps 1 thru 20 for left side fork. |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | Fork spring (2) | Not Sold Separately |
2 | Damper tube | Not Sold Separately |
Item | Description (Quantity) | Item | Description (Quantity) | |||
---|---|---|---|---|---|---|
A | Fork cap bolt | L | Stop, oil lock | |||
B | Fork plug | M | Bushing | |||
C | O-ring | N | Slider, fork (left side) | |||
D | Quad ring seal | O | Slider, fork (right side) | |||
E | Blow valve | P | Drain screw | |||
F | Rebound spring | Q | Screw with washer | |||
G | Slider tube | R | Axle holder | |||
H | Retaining ring | S | Washer | |||
I | Oil seal | T | Lock washer | |||
J | Spacer seal | U | Nut | |||
K | Bushing, slider |