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Fork Slider Kit (Black)
J026402013-11-01
GENERAL
Kit Number
46546-03
Models
For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Kit Contents
See Figure 1 and Table 1.
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)
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.
Special Tools Required
  • Air impact wrench
  • Torque wrench
  • Fork spring compressing tool
  • Damper rod extension tool
  • Fork Tube Holder HD-41177
  • Front Fork Oil Level Gauge HD-59000A
  • Fork Oil Seal Installer Tool HD-34634 (large dia.)
Service Parts
Figure 1. Service Parts
Table 1. Service Parts
Item
Description (Quantity)
Part Number
A
Right fork
Not sold separately
B
Left Fork (non-fairing models)
29960-85
C
Left Fork (Cartridge type, Fairing models)
29961-85
1
Rubber Washer (2)
2
Fork Tube Plug
3
O-Ring (2)
4
Wear Ring (2, w/o fairing) (1, w/fairing)
5
Fork Oil Seal (2)
6
Slider Bushing (2)
7
Fork Leg Bushing (2)
8
Fork Slider (Right)
46552-03
9
Fork Slider (Left)
46551-03
10
Drain Screw
45858-77
11
8mm Screw/Washer (2)
12
Stud (2)
13
Axle Holder
46550-03
14
Flat Washer (2)
6702
15
Lockwasher (2)
7041
16
Hex Nut (2)
7748W
17
Harley-Davidson TYPE "E" FORK OIL (16 oz.)
Part No. 99884-80 not shown
INSTALLATION
NOTE
Prior to installation of this kit, check the bore of the new black sliders to be certain they are free of dirt and debris or damage to the new sliders may occur.
  1. Support the motorcycle so the front end is off the floor and the forks are fully extended.
  2. See the Service Manual. Remove the front fender, front brake calipers, and front wheel
    3. NOTE
    On some models other parts will also need to be removed to access the front forks. See the Service Manual.
  3. See the Service Manual. On models so equipped, bleed the air-adjustable suspension.
  4. See the Service Manual. Drain and remove the front forks.
  5. See the Service Manual. Disassemble the front fork tubes and replace the original fork sliders with the black sliders from the kit.
  6. Assemble the front fork tubes, replacing the seals, bushings and other additional items as needed with new parts listed earlier.
    7. NOTE
    Do not use an impact wrench to tighten the drain screws. Use of an impact wrench may damage the screws.
  7. Tighten the drain screws to 52-78 in-lbs (5.8-8.8 Nm).
  8. See the Service Manual. Fill with TYPE E FORK OIL.
  9. See the Service Manual. Install the front fork and any parts that were removed to access the front forks. Install the front fender, wheel, and calipers.
  10. See the Service Manual. On models so equipped, refill the air-adjustable suspension system.
  11. Test ride vehicle to verify proper fork travel and rebound.