Special Tools

Description	Part Number	Qty.
FORK SEAL DRIVER AND DUST BOOT INSTALLER (43MM)	B-42571	1
FORK TUBE HOLDER	HD-41177	1
ROD CASE GUIDE SOCKET	HD-50083	1
FORK CAP WRENCH	HD-50084-A	1
HARLEY-DAVIDSON PRO-LEVEL OIL GAUGE	HD-59000-B	1

Consumables

Description	Part Number	Size
HARLEY-DAVIDSON SEAL GREASE	11300005	29.6 ml (1 fl oz)
TYPE "D" HYDRAULIC FORK OIL	62600098	0.47 L (16 fl oz)

Disassemble

Initial Disassembly

1.	See Figure 1. Clamp fork tube in fork tube holder. Mount in vise with fork vertical. Special Tool: FORK TUBE HOLDER (HD-41177)
2.	NOTE Record number of preload adjustment turns. Turn preload adjuster fully counterclockwise. See the owner's 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.	See Figure 3. Use fork cap wrench to remove fork tube cap (1). Special Tool: FORK CAP WRENCH (HD-50084-A)
4.	NOTE Have a suitable container ready to place components into after removal from tube. Remove joint rod assembly. a. Raise fork tube cap above fork tube (9). b. Use rod case guide socket to remove inner fork nut (3). Special Tool: ROD CASE GUIDE SOCKET (HD-50083) c. Remove joint rod (6) assembly.
5.	Remove spring seat (7).
6.	Remove spring (8).

1	Fork tube holder
2	Fork tube

Figure 1. Fork Tube Holder

Drain Fork Oil

1.	NOTE Drain fork oil into a suitable container. Drain fork oil. a. Slowly pump fork tube and fork slider at least ten times. b. Allow 10-15 minutes for fork to drain completely.
2.	If only performing a fork oil change, go to Fork Fill later in this procedure.

Joint Rod Disassemble

1.	See Figure 3. Disassemble joint rod assembly. a. Separate hex nut (4) from fork tube cap (1). b. Remove fork tube cap. c. Remove hex nut. d. Remove inner fork nut (3). e. Remove rebound spring (5).
2.	Discard O-ring (2).

Complete Disassembly

1.	See Figure 3. Separate fork tube from fork slider. a. Remove dust seal (15). b. Remove stopper ring (14) from groove inside fork tube (9). c. Expand fork slider (16) and fork tube against each other repeatedly (in a slide-hammer effect) to remove fork tube.
2.	Disassemble fork slider. a. Remove slider bushing (10). b. Remove guide bushing (11). c. Remove seal spacer (12). d. Discard oil seal (13). e. Remove stopper ring (14). f. Remove dust seal (15).

Clean and Inspect

1.	Clean all parts.
2.	Inspect parts for wear or damage. Replace parts as necessary.
3.	Inspect OD of slider bushing and ID of fork tube bushing. a. If coating is worn through (metallic substrate showing), replace bushing. b. Inspect for distortion. c. If deep scratches or scoring are found, replace bushing. Also inspect mating components for similar wear. Replace or repair as necessary.
4.	Check fork tube and fork slider for scoring, scratches and abnormal wear.
5.	Inspect slider tube for nicks from stones and road debris, especially in area where seal contacts it. Replace if necessary.
6.	See Figure 2. Check runout with a dial indicator. a. Set fork slider on V-blocks. b. Replace fork if runout exceeds: Dimension: 0.2 mm (0.008 in)

Figure 2. Measure Fork Tube Runout

Initial Assembly

1.	NOTE Lubricate all seal lips and O-rings with seal grease during assembly. HARLEY-DAVIDSON SEAL GREASE (11300005) See Figure 3. Assemble fork slider. a. Install dust seal (15). b. Install stopper ring (14). c. Install new oil seal (13) with lettering facing down. d. Install seal spacer (12). e. Install guide bushing (11). f. Install slider bushing (10). Expand bushing only enough to fit fork slider (16).
2.	Assemble fork slider to fork tube. a. Slide fork slider into fork tube. b. Seat oil seal with installer. Special Tool: FORK SEAL DRIVER AND DUST BOOT INSTALLER (43MM) (B-42571) c. Install stopper ring (14) into groove in fork tube. d. Seat dust seal with installer.

Joint Rod Assemble

1.	NOTE Lubricate all fork components during assembly. See Figure 3. Install new O-ring (2) on fork tube cap (1).
2.	Assemble joint rod assembly. a. Install rebound spring (5). b. Install inner fork nut (3). c. Install hex nut (4). d. Install fork tube cap (1). e. Tighten hex nut against fork tube cap. Torque: 26–30 N·m (19–22 ft-lbs) Fork piston rod hex nut, left side

Fork Fill

1.	Mount fork assembly in fork tube holder and fully compress assembly. Special Tool: FORK TUBE HOLDER (HD-41177)
2.	See Figure 3. Install spring (8).
3.	Install spring seat (7).
4.	Bleed fork assembly. a. Fill fork with fork oil to mid point of inner fork nut (3).TYPE "D" HYDRAULIC FORK OIL (62600098) b. Pump fork tube (9) 8-10 times to expel air from assembly. NOTE It is important the pumping procedure is performed. c. Fully compress assembly. d. Fill fork with fork oil until oil is above specified depth from top of fully compressed fork. Depth: 73 mm (2.87 in) e. Pump assembly 8-10 times to expel any additional air.
5.	NOTE Set fork oil level with assembly fully compressed. See Figure 4. Use fork oil level gauge to set oil level to specified depth. Depth: 73 mm (2.87 in) Special Tool: HARLEY-DAVIDSON PRO-LEVEL OIL GAUGE (HD-59000-B)

Complete Assembly

1.	Install joint rod assembly. a. Install joint rod (6) assembly in inner tube (16). b. Hand tighten inner fork nut (3). c. Using socket, tighten inner fork nut. Torque: 80–100 N·m (59–74 ft-lbs) Rod guide case, left side Special Tool: ROD CASE GUIDE SOCKET (HD-50083)
2.	NOTE Lubricate all seal lips and O-rings with HARLEY-DAVIDSON SEAL GREASE during assembly. See Figure 3. Install fork tube cap. a. Install fork tube cap (1). b. Use fork cap wrench. Tighten. Torque: 30–40 N·m (22–30 ft-lbs) Fork tube cap, left side Special Tool: FORK CAP WRENCH (HD-50084-A)
3.	Adjust preload. See the owner's manual.

Figure 3. Front Fork (Left Side)

Figure 4. Oil Level Gauge