1. | Support the motorcycle so the front end is off the floor and the forks are fully extended. | |||
2. | Remove front fender, front brake caliper(s), front wheel and front forks following the instructions in the CHASSIS section of the service manual. NOTE On some models other parts will also need to be removed to access the front forks. See the service manual. | |||
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) | ||||
3. | Disassemble the front fork tubes according to instructions in the service manual, and replace the original fork sliders with the sliders (see Figure 2 , items 1 and 3) from the kit. | |||
4. | Assemble the front fork tubes, replacing worn seals, bushings or other additional items as needed. Two new slider oil seals (5) are included in the kit. | |||
5. | Fill with TYPE E FORK OIL (Harley-Davidson part number 99884-80) according to the instructions found in the service manual. | |||
6. | Install the front fork and any parts that were removed to access the front forks. Install the front fender, wheel, and caliper according to the instructions found in the CHASSIS section of the service manual. NOTE The original equipment front fork reflectors located on both sliders will be removed, cleaned and installed on the new chrome sliders. Ambient temperature should be at least 60° F (16° C) for proper adhesion of the reflectors to the sliders. |
Figure 1. Reflector Placement | ||
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) | ||||
7. | Using a piece of dental floss (or similar material) in a back and forth motion, loosen the reflector (Figure 2, A and B) from fork slider at both ends. Rotate reflector from side to side until it can be removed. Retain reflector for future use. Repeat procedure on the opposite side fork slider. | |||
8. | Remove any excess adhesive from both reflectors. Surface must be clean for reinstallation. NOTE The bottom edge of the reflector should be two inches (50 mm) above the center of the axle shaft. | |||
9. | Peel the liner from one side of the foam double-sided tape. Position the tape to the back of the reflector, and press firmly into place. Peel the remaining liner from the tape. Place the reflector in position on the fork slider as shown in Figure 1 , and press firmly into place. Repeat the procedure on the opposite side fork slider. NOTE Allow AT LEAST 24 hours after applying the reflectors before exposing the area to vigorous washing, strong water spray or extreme weather. | |||
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) | ||||
10. | Pump brakes prior to test riding vehicle. | |||
11. | Test ride the vehicle to verify proper fork travel and rebound. |
Kit | Item | Description (Quantity) | Part Number |
---|---|---|---|
Kit 45500064 | 1 | Fork slider, right side (chrome) | 46587-06B |
2 | Axle cap (chrome) | 41860-06A | |
3 | Fork slider, left side (chrome) | 45500068 | |
4 | Tape, double sided foam (2) | 53791-06 | |
5 | Oil seal (2) | 46514-01A | |
Kit 45500065 | 1 | Fork slider, right side (chrome) | 48750-08A |
2 | Axle cap (chrome) | 41860-06A | |
3 | Fork slider, left side (chrome) | 45500069 | |
4 | Tape, double sided foam (2) | 53791-06 | |
5 | Oil seal (2) | 46514-01A | |
Kit 45500066 | 1 | Fork slider, right side (chrome) | 46587-06B |
2 | Axle cap (chrome) | 41860-06A | |
3 | Fork slider, left side (chrome) | 45500070 | |
4 | Tape, double sided foam (2) | 53791-06 | |
5 | Oil seal (2) | 46514-01A | |
Kit 45500067 | 1 | Fork slider, right side (chrome) | 45500072 |
3 | Fork slider, left side (chrome) | 45500071 | |
4 | Tape, double sided foam (2) | 53791-06 | |
5 | Oil seal (2) | 45875-84A | |
Kit 45500073 | 1 | Fork slider, right side (gloss black) | 45500100 |
2 | Axle cap (gloss black) | 45500103 | |
3 | Fork slider, left side (gloss black) | 45500099 | |
4 | Tape, double sided foam (2) | 53791-06 | |
5 | Oil seal (2) | 46514-01A | |
Kit 45500074 | 1 | Fork slider, right side (gloss black) | 45500100 |
2 | Axle cap (gloss black) | 45500103 | |
3 | Fork slider, left side (gloss black) | 45500101 | |
4 | Tape, double sided foam (2) | 53791-06 | |
5 | Oil seal (2) | 46514-01A | |
Original equipment parts that are reused: | |||
A | Reflector, amber, right | 59481-00 | |
B | Reflector, amber, left | 59482-00 | |
C | Axle cap washer (2) except FLD | 7062 | |
D | Axle cap bolt (2) except FLD | 4042 |