Special Tools
| Description | Part Number | Qty. |
|---|---|---|
| FORK SEAL DRIVER AND DUST BOOT INSTALLER (43MM) | B-42571 | 1 |
| FORK TUBE HOLDER | HD-41177 | 1 |
| FRONT FORK COMPRESSOR | HD-45966 | 1 |
| HARLEY-DAVIDSON PRO-LEVEL OIL GAUGE | HD-59000-B | 1 |
Consumables
Initial Assembly
NOTE
Lubricate all seal lips and O-rings with seal grease during assembly.
| 1. | See Figure 2. Assemble fork slider. a. Install dust seal (17). b. Install retaining ring (16). c. Install new oil seal (15) with lettering facing down. d. Install seal spacer (14). e. Install guide bushing (13). f. Install slider bushing (12). Expand bushing only enough to fit fork slider (18). g. Apply threadlocker to new screw (19). Install screw.LOCTITE 243 MEDIUM STRENGTH THREADLOCKER AND SEALANT (BLUE) (99642-97) h. Install centering plate (9) with damper (8). i. Install screw. Tighten. Torque: 15–25 N·m (133–221 in-lbs) Fork tube damper screw | |
| 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 retaining ring (16) into groove in fork tube. d. Seat dust seal with installer. |
Fork Fill
| 1. | Mount fork assembly in fork tube holder and fully compress assembly. Special Tool: FORK TUBE HOLDER (HD-41177) | |
| 2. | Install damper rod extension from front fork compressor tool on damper rod. | |
| 3. | Bleed fork assembly. NOTE Set fork oil level with assembly fully compressed. a. Fill fork with fork oil.TYPE "D" HYDRAULIC FORK OIL (62600098) b. See Figure 2. Pump fork slider (18) 8-10 times to expel air from assembly. NOTE It is important that 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: 99 mm (3.90 in) e. Pump assembly 8-10 times to expel any additional air. | |
| 4. | See Figure 1. Use fork oil level gauge to set oil level to specified depth. Depth: 99 mm (3.90 in) Special Tool: HARLEY-DAVIDSON PRO-LEVEL OIL GAUGE (HD-59000-B) |
Complete Assembly
NOTE
Install spring tapered end up.
| 1. | See Figure 2. Install spring (10). | |
| 2. | Install spring joint (7). | |
| 3. | Install spring collar (6). | |
| 4. | Install spring seat stop (3). | |
| 5. | Install seal (5). | |
| 6. | Install new O-ring (2). | |
| 7. | See Chassis → FRONT FORK → Disassemble → Compress Fork Spring. Compress fork using front fork compressor. Special Tool: FRONT FORK COMPRESSOR (HD-45966) NOTE
a. See Figure 2. Compress spring (10) enough to allow damper (8) to be raised above spring seat stop (3). b. Remove extension tool while holding damper. c. See Chassis → FRONT FORK → Disassemble → Compress Fork Spring. Fully install nut (1) on damper. | |
| 8. | Install fork tube cap. a. See Figure 2. Fully install fork tube cap (1) on damper (8). b. Tighten hex nut (4) against fork tube cap. Torque: 17.5–22.5 N·m (13–17 ft-lbs) Fork damper nut c. Install fork tube cap (1). Tighten. Torque: 30–40 N·m (22–30 ft-lbs) Fork tube cap | |
| 9. | Adjust preload. See the owner's manual. |
| 1 | Fork oil level |
| 2 | Tube |
| 3 | Collar |
| 4 | Thumb lock |
Figure 1. Oil Level Gauge
| 1 | Fork tube cap |
| 2 | O-ring |
| 3 | Spring, seat stop |
| 4 | Hex nut |
| 5 | Seal |
| 6 | Spring collar |
| 7 | Spring joint |
| 8 | Damper |
| 9 | Centering plate |
| 10 | Spring |
| 11 | Fork tube |
| 12 | Slider bushing |
| 13 | Guide bushing |
| 14 | Seal spacer |
| 15 | Oil seal |
| 16 | Retaining ring |
| 17 | Dust seal |
| 18 | Fork slider (left; right similar) |
| 19 | Screw |
Figure 2. Front Fork Components