CHROME/BLACK FORK SLIDER KIT
J064422017-08-22
GENERAL
Kit Numbers
(Chrome) 45500399, 45500400, 45500401, 45500402, 45500406
(Black) 45500403, 45500404, 45500405
Models
For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
These kits are a direct replacement for the original equipment (OE) fork sliders, and install in the same manner.
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 62600026)
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 refers to service manual information. A service manual for this year/model motorcycle is required for this installation and is available from a Harley-Davidson dealer.
PREPARATION
NOTE
For vehicles equipped with security siren:
- Verify that the hands-free fob is present. Turn ignition switch ON.
For Vehicles With Main Fuse:
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
- See the service manual and remove the main fuse.
REMOVAL
WARNINGWear 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)
- Raise the front end of the motorcycle.
- See the service manual to remove the front fender, front brake calipers and front wheel.
- Remove, drain and disassemble the front forks per the service manual.
- See the service manual to clean and inspect all parts not being replaced for wear or damage. Replace items as necessary.
- For models with fork-mounted reflectors: Using a piece of dental floss (or similar material) in a back and forth motion, loosen the top and bottom of the reflector from the fork slider. Rotate the reflector from side to side until it can be removed. Save the reflector for later assembly. Repeat for the remaining reflector. Peel off any excess adhesive from both reflectors.
NOTE
On some models, additional parts must also be removed to access the front forks. See the service manual.
INSTALLATION
The fork sliders included in these kits install in the same manner as the original equipment parts. See the service manual for proper installation procedures.
Pay close attention to all warnings, cautions and torque specifications when installing these fork sliders.
NOTE
Check the bores of the new sliders before installation. Dirt and debris can damage the sliders.
| 1. | Assemble the front fork tubes per service manual instructions, with the following exceptions: a. Replace the original fork sliders with the new chrome or black sliders (see Figure 2 , items 1 and 4) from the kits. b. Replace the original slider oil seal on each side with a new slider oil seal (3) from the kit. c. Replace any other worn seals, bushings or other items as needed. | |
| 2. | Fill the front forks with Type "E" Hydraulic Fork Oil (Part No. 62600026) following service manual instructions. | |
| 3. | Install two new O-rings (2) on the fork tube plugs from the kit. | |
| 4. | Complete the assembly of the front fork tubes per service manual instructions. | |
| 5. | Install the front forks to the motorcycle per the service manual. Install the front wheel, front brake calipers, front fender and any additional items removed earlier. | |
| 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) | ||
| 6. | For models with fork-mounted reflectors: |
- 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).
- Parts cannot be repositioned after initial adhesive installation.
- Allow at least 24 hours after application before exposing the area to vigorous washing, strong water spray or extreme weather.
- The adhesive bond will increase to maximum strength after about 72 hours at normal room temperature.
- Do not clean with denatured alcohol, mineral spirits or other solvents. Damage to components occurs.
- Clean back of reflector with a mixture of 50 percent isopropyl alcohol and 50 percent distilled water. Allow to dry completely.
- Peel the liner from one side of the double-sided foam tape (see Figure 2 , item 5). Position the tape to the back of the reflector. Press firmly into place. Repeat for the remaining reflector.
- Clean the reflector mounting area of the fork slider with a mixture of 50 percent isopropyl alcohol and 50 percent distilled water. Allow to dry completely.
- Peel the remaining liner from the tape. Place the reflector in position on the fork slider. Locate the bottom edge of the reflector 58.67 mm (2.31 in) above the center of the axle shaft as shown. Press firmly into place. Hold the reflector in position with steady pressure for approximately one minute. Repeat for the remaining reflector.
NOTE
Per regulations: Reflector to be placed on center line perpendicular to side view.
| 1 | Install bottom of reflector 2.31 inches (58.67 mm) above center of axle |
Figure 1. Reflector Placement
COMPLETION
NOTE
Verify that the ignition switch is in the OFF position before installing the main fuse or attaching the negative battery cable.
| 1. | See the service manual and install the main fuse. | |
| 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) WARNINGAfter 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) | ||
| 2. | Pump the brakes before test riding the motorcycle. | |
| 3. | Test ride the vehicle to verify proper fork travel and rebound. |
SERVICE PARTS
Figure 2. Service Parts: Chrome/Black Fork Sliders
Table 1. Service Parts
Item | Description (Quantity) | Part Number | From Kit |
|---|---|---|---|
1 | Fork slider, right (chrome) | 45500408 | 45500399 |
45500410 | 45500400 | ||
45500412 | 45500401 | ||
45500414 | 45500402 | ||
45500423 | 45500406 | ||
Fork slider, right (black) | 45500416 | 45500403 | |
45500418 | 45500404 | ||
45500420 | 45500405 | ||
2 | 0-ring (2) | 46508-01 | All |
3 | 49 mm Oil seal (2) | 46514-01A | |
4 | Fork slider, left (chrome) | 45500407 | 45500399 |
45500409 | 45500400 | ||
45500411 | 45500401 | ||
45500413 | 45500402 | ||
45500422 | 45500406 | ||
Fork slider, left (black) | 45500415 | 45500403 | |
45500417 | 45500404 | ||
45500419 | 45500405 | ||
5 | Tape, double-sided foam (2) | 53791-06 | All |
6 | Copper packing washer (2) | 46615-06 | |
7 | Bolt, Hex socket (2) | 46614-06 |