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 rebound and compression adjuster turns. Remove rebound and compression adjustments. See the owner's manual. a. Turn rebound adjuster fully counterclockwise. b. Turn compression adjuster fully counterclockwise.
	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 4. Use fork cap wrench to remove fork tube cap (1). Special Tool: FORK CAP WRENCH (HD-50084-A)
4.	See Figure 4. If only performing a fork oil change, remove fork tube cap. a. Separate hex nut (6) from fork tube cap (1). b. Remove fork tube cap. c. Go to Drain Fork Oil later in this procedure.
5.	NOTE Have a suitable container ready to place components into after removal from tube. Remove piston rod assembly with rod guide case. a. Raise fork tube cap above fork tube (12). b. Use rod case guide socket to remove rod guide case (5). Special Tool: ROD CASE GUIDE SOCKET (HD-50083) c. Remove piston rod assembly (8) and rod guide case.
6.	Remove spring collar (10).
7.	Remove spring (11).

1	Fork tube holder
2	Fork tube

Figure 1. Fork Tube Holder

Drain Fork Oil

1.	NOTE Drain fork oil into a suitable container. NOTE If only performing a fork oil change, do not allow pushrod or pushrod tube in center of piston rod assembly to be damaged. 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.

Piston Rod Disassemble

1.	See Figure 4. Disassemble piston rod assembly. a. Separate hex nut (6) from fork tube cap (1). b. Remove fork tube cap. c. Remove hex nut. d. Remove rod guide case (5). e. Remove rebound spring (7). f. Discard piston ring (9).
2.	Disassemble rod guide case. a. Discard O-ring (4). b. Discard slider ring (3).
3.	Discard O-ring (2).

Complete Disassembly

1.	See Figure 4. Separate fork tube from fork slider. a. Remove dust seal (18). b. Remove stopper ring (17) from groove inside fork tube (12). c. Expand fork slider (19) and fork tube against each other repeatedly (in a slide-hammer effect) to remove fork tube.
2.	Disassemble fork slider. a. Remove slider bushing (13). b. Remove guide bushing (14). c. Remove seal spacer (15). d. Discard oil seal (16). e. Remove stopper ring. f. Remove dust seal (18).

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 slider for scoring, scratches and abnormal wear.
5.	Inspect fork 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 4. Assemble fork slider. a. Install dust seal (18). b. Install stopper ring (17). c. Install new oil seal (16) with lettering facing down. d. Install seal spacer (15). e. Install guide bushing (14). f. Install slider bushing (13). Expand bushing only enough to fit fork slider (19).
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 (17) into groove in fork tube. d. Seat dust seal with installer.

Piston Rod Assemble

1.	NOTE Lubricate all fork components during assembly. See Figure 1. Install new O-ring (2) on fork tube cap (1).
2.	Assemble rod guide case. a. Install new O-ring (4) on rod guide case (5). b. Install new slider ring (3) on rod guide case.
3.	Assemble piston rod assembly. a. Install preload spring (7) on piston rod assembly (8). b. Install rod guide case. c. Install piston ring (9). d. Fully install hex nut (6).

Assemble For Fork Fill

1.	Mount fork assembly in fork tube holder and fully compress assembly. Special Tool: FORK TUBE HOLDER (HD-41177)
2.	See Figure 4. Install spring (11).
3.	Install spring collar (10).
4.	NOTE Do not damage slider ring (3) on rod guide case (5). NOTE Lubricate all seal lips and O-rings with HARLEY-DAVIDSON SEAL GREASE during assembly. Install piston rod assembly. a. Install piston rod assembly (8) in fork slider (19). b. Hand tighten rod guide case (5). c. Pull up on fork tube (12) to fit slider ring to outer tube. d. Using socket, tighten rod guide case. Torque: 80–100 N·m (59–74 ft-lbs) Rod guide case, right side Special Tool: ROD CASE GUIDE SOCKET (HD-50083)

Fork Fill

1.	Bleed fork assembly. a. Fill fork with fork oil to mid point of rod guide case (5).TYPE "D" HYDRAULIC FORK OIL (62600098) b. Pump fork tube (12) 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: 57 mm (2.24 in) e. Pump assembly 8-10 times to expel any additional air.
2.	NOTE Set fork oil level with assembly fully compressed. See Figure 3. Use fork oil level gauge to set oil level to specified depth. Depth: 57 mm (2.24 in) Special Tool: HARLEY-DAVIDSON PRO-LEVEL OIL GAUGE (HD-59000-B)

Complete Assembly

1.	See Figure 4. Install fork tube cap on piston rod assembly. a. Fully install fork tube cap (1). b. Tighten hex nut against fork tube cap. Torque: 26–30 N·m (19–22 ft-lbs) Fork piston rod hex nut, right side
2.	Install fork tube cap. a. Install fork tube cap (1). b. Tighten. Torque: 30–40 N·m (22–30 ft-lbs) Fork tube cap, right side Special Tool: FORK CAP WRENCH (HD-50084-A)
3.	Adjust preload. See the owner's manual.

Figure 3. Oil Level Gauge

Figure 4. Front Fork (Right Side)