KNOCKOUT CUSTOM WHEEL KIT
J065772021-10-19
GENERAL
WARNINGThe rider's safety depends upon the correct installation of this kit. Dealer installation is required for vehicles equipped with ABS brakes. Proper installation of this kit requires the use of special tools available only through a Harley-Davidson Dealer. An improperly serviced brake system can adversely affect brake performance, which could result in death or serious injury. (00578b)
WARNINGInstall only wheels and installation kits approved for your model motorcycle. Contact a Harley-Davidson dealer to verify fitment. Mismatching wheels and installation kits or installing wheels not approved for your model can cause loss of control, which could result in death or serious injury. (00610c)
Kit Number
43300494 and 43300496
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 requires the following special items.
Front Fork Lowering Requirements:
- 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)
- Front Fork Spring Compressing Tool (HD-45966)
- Extension Tool (HD-45966-1)
Knockout 21" Front Wheel Requirements:
Accessory hub caps are not compatible with this wheel.
- Wheel Installation Kit NON ABS (41455-08C), With ABS (41454-08B)
- (10) Brake Disc/Hub Cap Screws (3655A) or (2) Chrome Screw kits (46646-05)
- Wheel Bearing Remover and Installer (94134-09)
- Tire: (43100008)
- Rotors: See catalog for approved rotor fitment.
- Fender: See catalog for approved fender fitment.
Knockout 18" Rear Wheel Requirements:
- Wheel Installation Kit NON ABS (41456-08C), With ABS (41453-08C)
- (5) Brake Disc Screws (43567-92 or 46647-05)
- Wheel Bearing Remover and Installer (94134-09)
- Tire: (44006-09)
RECOMMENDED ADDITIONAL PARTS
The following Harley-Davidson Genuine Motor Accessories are recommended for proper maintenance and cleaning:
- Harley® Bright™ Chrome Cleaner (94683-99)
- Harley® Glaze™ Polish and Sealant (99701-84)
- Harley® Wheel and Spoke Brush (43078-99)
- Harley-Davidson® Wheel and Tire Cleaner (94658-98)
- Harley® Preserve™ Bare Aluminum Protectant (99845-07)
REMOVAL
NOTE
This instruction sheet references service manual information. A service manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer.
| 1. | Figure 1 Remove and disassemble existing front wheel assembly. If the front brake disc diameter does not measure 3.25 in., discard the discs. Save axle, axle nut, and wheel spacers for kit installation. See service manual. | |
| 2. | See the I-sheet that came with new front fender or service manual. Remove front fender. | |
| 3. | Figure 2 Remove and disassemble existing rear wheel assembly. Parts listed are needed for reassembly. See service manual. | |
| 4. | See the service manual. Remove front forks. |
| 1 | Diameter |
Figure 1. Disc Mounting Hole Diameter
| 1 | Rear Axle |
| 2 | Spacer |
| 3 | Bearing (2) |
| 4 | Spacer |
| 5 | Sprocket |
| 6 | Isolator |
| 7 | Brake disc |
| 8 | Spacer, non ABS |
| 9 | E-clip |
| 10 | Nut |
| 11 | Axle cam |
| 12 | Wheel speed sensor, ABS |
| 13 | Clip |
Figure 2. Rear Wheel Parts for Reuse
PREPARATION
Prepare the Front Wheel
NOTE
Do not install the bearing shim included in the installation kit.
NOTICE
Do not re-use brake disc/rotor screws. Re-using these screws can result in torque loss and damage to brake components. (00319c)
| 1. | Install the wheel installation kit. a. ABS equipped: 41454-08B. b. NON ABS equipped: 41455-08C. | |
| 2. | NOTE See Figure 7. The machined groove on the front wheel indicates the primary bearing side of the wheel and will mount facing the left side on motorcycle. | |
| 3. | See the service manual. Assemble front wheel components. |
Prepare the Rear Wheel
NOTE
Do not install the bearing shim included in the installation kit.
NOTICE
Do not re-use sprocket mounting screws. Re-using sprocket mounting screws can result in torque loss and damage to the sprocket and/or belt assembly. (00480b)
| 1. | Install the wheel installation kit. a. ABS equipped: 41453-08C. b. NON ABS equipped: 41456-08C. | |
| 2. | NOTE See Figure 8. The machined groove on the rear wheel indicates the primary bearing side of the wheel and mounts on the right side of the motorcycle. | |
| 3. | See the service manual. Assemble rear wheel components. |
Mounting the Tires
| 1. | See Figure 7 and Figure 8 and the service manual. Install short valve stem (43157-83A) on front and rear wheels. | |
| 2. | NOTE Only install the required (separately purchased) tire. If the wheel has a yellow dot sticker on the rim, orient the tire so the white dot on the tire is opposite of the sticker. If the wheel has a green dot sticker on the rim, orient the tire so the white dot on the tire is aligned with the sticker. If no rim dot sticker is present, see the service manual. NOTE Use plastic protectors on tire mounting tools and rim clamps when mounting a tire to a painted wheel. When mounting tires, liberally use tire lube on the wheel and tire. a. Front Tire: 43100008 b. Rear Tire: 44006-09 | |
| 3. | See the service manual. Install front brake discs on the wheel. | |
| 4. | See the service manual. Install the stock rear brake disc and sprocket on the wheel. |
Prepare the Front Fork Assembly
| 1. | See Figure 3. Install fork in Fork Tube Holder (HD-41177) as follows: a. Clamp end of tool (1) in vise in a horizontal position. b. See Figure 6. With the fork bolt (A) upward, clamp fork tube (9), between rubber pads on inboard side of tool. Tighten knobs until fork tube is securely held. NOTE Be aware that fork bolt (A) is under spring-pressure, so have a firm grasp on bolt as the last thread is turned. | |
| 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) | ||
| 2. | Slowly remove fork bolt and O-ring (1) from fork tube. Discard O-ring. | |
| 3. | Remove the spring collar (F), flat washer (H) and spring (2) from the fork tube. Save spring collar and flat washer for later use. | |
| 4. | Remove fork assembly from fork tube holder. Turn fork upside down over drain pan to drain oil. For best results, slowly pump fork tube and fork slider (G) at least 10 times. | |
| 5. | Install fork spring and spring collar back into fork tube. | |
| 6. | Put a shop rag on the floor. Turn the fork assembly upside down. Press the end of the spring collar against the rag. Compress the spring. Remove the screw (7) with copper washer (6) from the bottom end of fork slider. Use air impact wrench for best results. Discard screw and copper washer. | |
| 7. | Remove and discard fork spring. | |
| 8. | Push the damper tube (8) and rebound spring (5) free of fork tube by inserting a small diameter rod through the opening in the bottom of tube. Discard damper tube and rebound spring. | |
| 9. | Using pick tool, remove retaining clip (C) between fork slider and fork tube. Do not expand or stretch retaining clip to remove from fork tube or clip may be damaged. NOTE To overcome any resistance, use the fork tube as a slide hammer: Push fork tube into fork slider and then pull it outward with a moderate amount of force. Repeat this sequence until fork tube separates from fork slider. | |
| 10. | Remove fork tube from fork slider. | |
| 11. | Slide fork oil seal (4), spacer seal (D) and slider bushing (E) off end of fork tube. Discard fork oil seal. | |
| 12. | Remove oil lock (3) from the end of fork tube (9) or the inside of the fork slider. Discard oil lock and fork tube. |
| 1 | Vise grip |
| 2 | Rubber pad |
| 3 | Plastic knob |
Figure 3. Fork Tube Holder (HD-41177)
Fork Assembly
NOTICE
Exercise caution to avoid scratching or nicking fork tube. Damaging tube can result in fork oil leaks after assembly. (00421b)
NOTE
Inspect parts for wear or damage. Replace or repair as necessary.
| 1. | See Figure 6. Make sure that piston ring is installed on the damper tube with the cut-outs down. Place new rebound spring (5) on new damper tube from kit (8). Insert damper tube into new fork tube (9). | |
| 2. | Insert new spring (2) and spring collar (F) into fork tube, with dense section of coils toward damper tube. Push bottom of damper tube through the opening at the bottom end of the fork tube. Place new oil lock (3) over end of damper tube. | |
| 3. | Apply Loctite 565 Thread Sealant to new screw (7). Position fork tube and damper tube in fork slider (G). Hold the assembly in place by exerting pressure on the spring. Install screw (7) with new copper washer (6) from kit. | |
| 4. | Tighten screw. Torque: 45 ± 5 N·m (33 ± 4 ft-lbs) | |
| 5. | Coat inner diameter (ID) and outer diameter (OD) of slider bushing (E) with clean fork oil. Slide slider bushing down fork tube (either direction). | |
| 6. | Slide spacer seal (D) down fork tube until it contacts slider bushing (either direction). | |
| 7. | Coat the ID of the new fork oil seal (4) 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 spacer seal. | |
| 8. | See Figure 4. Obtain the Fork Seal/Bushing Tool (HD-45305) and proceed as follows: a. Slide the fork seal installer down the fork tube until it contacts the fork oil seal. b. See Figure 4. Using the tool like a slide hammer, drive fork oil seal (with spacer seal and slider bushing) down the fork tube until retaining clip groove is visible in fork slider ID. c. See Figure 6. Slide the retaining clip (C) 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 be damaged. | |
| 9. | Remove spring collar and fork spring. | |
| 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) | ||
| 10. | Fill fork tube as follows: a. With fork tube compressed, pour Harley-Davidson Type E Fork Oil into the fork tube almost to the top. b. Pump fork tube ten times to remove air from system. | |
| 11. | Adjust the fork oil level, so that it is 91 mm (3.58 in) from the top of the fork tube with the fork tube compressed and the fork spring, spring collar and flat washer removed. Proceed as follows: a. See Figure 5. 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 91 mm (3.58 in) from the bottom of the rod. Tighten thumbscrew. c. Push the plunger on the cylinder all the way in. d. See Figure 6. 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 11(c) through 11(f). Level is correct when no fork oil is observed being drawn through transparent tube. | |
| 12. | Install fork spring into the fork tube with the dense end down. NOTE Verify the fork spring is installed with dense section of coils to the bottom. | |
| 13. | Install flat washer (H) on top of spring. | |
| 14. | Install spring collar (F) on top of washer. | |
| 15. | Install new O-ring (1) onto fork bolt (A). | |
| 16. | Install fork tube bolt. Tighten. Torque: 55 ± 25 N·m (41 ± 18 ft-lbs) |
Figure 4. Install Fork Oil Seal
Figure 5. Remove Excess Fork Oil (HD-59000B)
LEFT SIDE
Repeat steps for prepare the front fork and fork assembly.
INSTALLATION
| 1. | See the service manual. Install the front forks. | |
| 2. | NOTE IMPORTANT: ABS must be re-flashed. Special Tool: DIGITAL TECHNICIAN II (HD-48650) a. Choose the REFLASH icon. b. Follow the on-screen prompts. | |
| 3. | See the information sheet that came with the new front fender. Install the front fender. | |
| 4. | NOTE Install the front wheel so that the valve stem is on the right side. | |
| 5. | See the service manual. Install rear wheel. | |
| 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) WARNINGWhenever 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) | ||
| 6. | Pump brakes to build system pressure. |
Test Ride
- Test ride motorcycle to verify fork travel and rebound.
SERVICE PARTS
Figure 6. Service Parts: Touring Cartridge Front Fork
Table 1. Service Parts Table: Touring Cartridge Front Fork
Item | Description (Quantity) | Part Number |
|---|---|---|
Stock Fork Assembly, Non-cartridge Fork from Kit | ||
Front fork items included in kit: | ||
1 | O-ring (2) | 46508-01 |
2 | Fork spring (2) | Not sold separately |
3 | Oil lock (2) | Not sold separately |
4 | Fork oil seal (2) | 46514-01A |
5 | Rebound spring (2) | Not sold separately |
6 | Washer (2) | 46615-06 |
7 | Screw, M14 (2) | 45500118 |
8 | Damper tube with piston ring (2) | Not Sold Separately |
9 | Fork tube (2) | 45500537 |
Front fork Items mentioned in text, but not included in kit: | ||
A | Fork bolt (2) | |
B | Bushing, fork tube (2) | |
C | Retaining clip (2) | |
D | Spacer seal (2) | |
E | Slider bushing (2) | |
F | Spring collar (2) | |
G | Fork slider (2) | |
H | Flat washer (2) | |
Figure 7. Service Parts: Knockout Front Wheel
Table 2. Service Parts: Knockout Front Wheel
Item | Description (Quantity) | Part Number |
|---|---|---|
Front wheel Items included in kit: | ||
1 | Wheel | Not sold separately |
2 | Machined groove | |
Front wheel installation kit item, discard extra items: | ||
A | Bearing (2 non ABS models, 1 ABS models) | 9276A |
B | Bearings (1 ABS models) | 9252 |
C | Axle sleeve | 41900-08 |
D | Short valve Stem | 43157-83A |
E | Valve stem cap | 41123-79 |
Figure 8. Service Parts: Knockout Rear Wheel
Table 3. Service Parts: Knockout Rear Wheel
Item | Description (Quantity) | Part Number |
|---|---|---|
Rear wheel Items included in kit: | ||
1 | Wheel | Not sold separately |
2 | Machined groove | |
Rear wheel installation kit items, discard extra items: | ||
A | Bearing (2 non ABS models, 1 ABS models) | 9276A |
B | Bearing (1 ABS models) | 9252 |
C | Axle sleeve | 41349-07 |
D | Short Valve Stem | 43157-83A |
E | Valve stem cap | 41123-79 |