Harley Davidson 1986-2003 XL/XLH Sportster. Service Manual — page 38

6. Install the slider over the damper rod (Figure 33) and
onto the fork tube until it bottoms. Make sure the oil lock
piece is still mounted onto the end of the damper rod.

7. Install the washer onto the damper rod Allen bolt.

8. Apply a non-permanent thread locking compound to
the damper rod Allen bolt threads prior to installation. In-
sert the bolt (Figure 34) through the lower end of the
slider and thread it into the damper rod. Tighten the bolt
securely.

9. Remove the fork cap and fork spring (Figure 32).

NOTE

The slider bushing, seal spacer and oil seal
are installed into the slider at the same time
with a suitable driver placed over the fork
tube and against the oil seal. A fork seal
driver (part No. HD-36583 or equivalent)
can be used. A piece of pipe can also be used
to drive the parts into the slider. When using a
piece of pipe or similar tool, do not damage to
the slider, oil seal or fork tube. Wrap both
ends of the pipe or tool with duct tape to pre-
vent it from scratching the fork tube and tear-
ing the oil seal.

10. Install the slider bushing, seal spacer and oil seal (Fig-
ure 35) at the same time. Perform the following:

a. Coat the slider bushing (A, Figure 35) with fork oil

and slide the bushing down the fork tube and rest it
against the slider bore.

b. Install the seal spacer (B, Figure 35) over the fork

tube with the concave side facing down. Rest the seal
spacer on the slider bushing.

c. Slide a new oil seal (C, Figure 35) over the fork tube

with the closed side facing up. Rest the oil seal on the
seal spacer.

d. Slide the fork seal driver down the fork tube (Figure

36).

e. Drive the bushing, seal spacer and oil seal into the

slider until the retaining ring groove in the slider can
be seen above the top surface of the oil seal.

f. Remove the fork seal driver.

FRONT SUSPENSION AND STEERING

509

14

31

32

33

34

35

11. Install the retaining ring (Figure 37) into the slider
groove. Make sure the retaining ring is fully seated in the
groove.
12. Slide the dust seal (Figure 38) down the fork tube and
seat it into the top of the slider.
13. Install the dust cover (Figure 39) as follows:

a. Slide the dust cover down the fork tube and rest it

against the top of the slider.

b. Slide one of the discarded oil seals down the fork

tube and rest it against the dust cover.

c. Use the same fork seal driver used in Step 10 and

carefully drive the dust cover onto the top of the
slider as shown in Figure 39.

d. Remove the installation tool and old oil seal.

14. Fill the fork tube with the correct quantity of Type E
Fork Oil or equivalent listed in Table 1.
15. The fork spring is tapered at one end. Install the spring
(Figure 32) so that the tapered end faces toward the bottom
of the fork.
16. Lubricate the fork cap O-ring and threads with new
fork oil.
17. On 1988-2003 models, align the fork cap with the
spring (Figure 32) and push down on the cap to compress
the spring. Start the cap slowly, don’t cross thread it. Place
the slider in a vise with soft jaws and tighten the fork cap se-
curely.
18. Install the fork tube as described in this chapter.
19. Install the fork cap on 1986-1987 models after fork in-
stallation.

FRONT FORK

(1200S MODELS)

The front suspension consists of a spring-controlled, hy-

draulically dampened telescopic fork.

Before suspecting major trouble, drain the front fork oil

and refill with the proper type and quantity (Chapter
Three). If the trouble persists, such as poor damping, a ten-
dency to bottom or top out, or leaks around the seals, follow
the service procedures in this section.

To simplify fork service and to prevent the mixing of

parts, remove, service and install the legs individually.

Front Fork Adjustment

Suspension preload adjustment

Adjust the front and rear spring preload before making

any other suspension adjustments. An assistant is required
to determine proper preload adjustment for a particular load
on the motorcycle.
1. Remove the motorcycle from the sidestand, then bounce
the suspension several times to make sure nothing is bind-
ing.
2. With the motorcycle unloaded, measure the rear suspen-
sion length and the front suspension length.

510

CHAPTER FOURTEEN

36

37

38

39

a. The rear suspension length is the distance from the

center of the upper shock nut to the center of the
lower shock nut (A, Figure 40).

b. The front suspension length is the distance from the

center of the front axle to the bottom of the lower tri-
ple clamp (B, Figure 40).

3. Load the full gear onto the motorcycle.
4. Measure the rear-suspension length and front-suspen-
sion length of the loaded motorcycle.

WARNING

Preload must be equal on both sides of the
motorcycle. Set both rear shock-absorber
preload cams to the same setting. Also set

both fork adjusting nuts to the same setting.
Handling will be adversely affected if preload
is not the same on both sides of the motorcy-
cle.

5. Subtract the loaded suspension length from the un-
loaded suspension length. The difference must be 0.5-1.0
inches (12.7-25.4 mm). Adjust the preload if the difference
is not within the specification.

a. To adjust the front preload, turn the preload adjuster

(A, Figure 41) with a 7/8-in. wrench. Turning the nut
clockwise increases front preload; counterclockwise
decreases the preload.

b. To adjust the rear preload, refer to

Shock Absorber

in

Chapter Fifteen.

Front fork damping adjustment

The 1200S fork is adjustable for compression and re-

bound damping.
1. Adjust the preload as described in the

Suspension

Preload Adjustment

in this section.

WARNING

Compression and rebound damping settings
must be equal on both sides of the motorcycle.
Handling will be adversely affected if damp-
ing is not the same on both fork legs.

2. The front fork on the 1200S has 14 compression damp-
ing settings. Setting 1 (fully clockwise) is the hardest; set-
ting 14 (fully counterclockwise) is the softest. The
recommended setting is 13 clicks from the hardest setting.

NOTE

To ensure the desired results, do not adjust the
damping more than two clicks without testing
the setting.

a. Turn the compression damping adjuster (B, Figure

41) one or two clicks. Turning the adjuster clockwise
increases compression damping, counterclockwise
decreases compression damping.

b. Turn the compression damping adjuster on the other

fork leg to the same setting.

c. Test ride the motorcycle.
d. Repeat the above steps until the desired compression

damping is obtained.

3. The 1200S front fork has 15 rebound damping settings.
Setting 1 (fully clockwise) is the hardest; setting 15 (fully
counterclockwise) is the softest. The recommended setting
is 8 clicks from the hardest setting.

a. Turn the rebound damping adjuster (C, Figure 41)

one or two clicks. Turning the rebound adjuster
clockwise increases rebound damping; counterclock-
wise decreases rebound damping.

b. Turn the rebound damping adjuster on the other fork

leg to the same setting.

FRONT SUSPENSION AND STEERING

511

14

40

41

c. Test ride the motorcycle.
d. Repeat the above steps until the desired rebound

damping is obtained.

Removal

Refer to Figure 42.

1. Support the motorcycle so the front wheel clears the
ground. Make sure the motorcycle is stable before remov-
ing the front wheel and fork legs.
2. Remove the front wheel (Chapter Thirteen).
3. Remove the front fender (Chapter Seventeen).

NOTE

Label the left and right fork legs so they can
be reinstalled in their original positions.

4. Loosen the upper fork bracket pinch bolt.
5. If the fork legs are going to be disassembled, loosen but
do not remove the fork cap.
6. Loosen the lower fork-bracket pinch bolt, and slide the
fork leg out of the fork brackets. If necessary, rotate the fork
leg while removing it.
7. If fork service is required, refer to

Disassembly

in this

section.

Installation

1. Clean any corrosion or dirt from the upper and lower
fork-bracket receptacles.

NOTE

The fork assemblies must be reinstalled on the
correct side of the motorcycle so the brake cal-
iper and front fender can be properly installed.

2. Install each fork leg so that the tube extends 1.735-1.745
in. (44.1-44.3 mm) above the upper fork bracket as shown
in Figure 43.
3. Tighten the lower bracket pinch bolt to 30 ft.-lb. (41
N•m).
4. Tighten the upper bracket pinch bolt to 30 ft.-lb. (47
N•m).
5. Install the front fender (Chapter Seventeen).
6. Install the front wheel (Chapter Thirteen).
7. Apply the front brake and pump the front fork several
times to seat the fork and front wheel.

Disassembly

To simplify fork service and to prevent the mixing of

parts, the legs should be disassembled and assembled indi-
vidually.

Refer to Figure 42.

NOTE

Fork holding tools are available (

Figure 11

,

typical), and such a tool may be shown in the

following illustrations. However, the text re-
fers to the use of a vise as a holding tool.

1. Clamp the fork axle boss at the bottom of the slider in a
vise with soft jaws. Do not clamp the slider at any point
above the fork axle boss.

512

CHAPTER FOURTEEN

42

FRONT FORK

(1995-2003 1200S MODELS)

1. Rebound adjuster
2. Fork cap
3. O-ring
4. Spacer
5. Spring collar
6. Fork spring
7. Damper
8. Fork tube
9. Dust cover

10. Dust seal

11. Retaining ring
12. Oil seal
13. Spacer seal
14. Slider bushing
15. Lower stop
16. Slider
17. Compression

damping adjuster

18. Washer
19. Allen bolt

43

1.735-1.745 in.
(44.1-44.3 mm)

NOTE

Loosen the bottom Allen bolt before removing
the fork cap and spring. Leaving the cap on
provides spring tension against the damper
rod. This prevents the damper rod from spin-
ning while attempting to loosen the Allen bolt.

2. Loosen, but do not remove, the Allen bolt at the bottom
of the slider (Figure 44).

NOTE

Do not remove the rebound adjuster (2,

Fig-

ure 45)

from the damper rod. If it is removed,

the adjuster will have to be reset during as-
sembly.

3. Remove the stopper ring (1, Figure 45), and remove the
spring preload adjuster (3, Figure 45).

WARNING

Stay clear of the fork cap when removing it.
The fork cap is under spring pressure, and it
may fly off when loosened. In addition, make
sure the fork tube is fully extended from the
slider. If the fork tube is damaged and stuck in
a compressed state, have a dealership disas-
semble the fork.

4. Unscrew the fork cap from the fork tube. The fork leg
will fall away from the cap.
5. Install the fork spring compressor (A, Figure 46; part
No. HD-41549A) onto the spring collar. Tighten the screws
on the compressor so they engage the holes in the spring
collar.
6. Use the tool to compress the spring and have an assistant
insert the fork spring plate tool (B, Figure 46; part No.
HD-41551) between the upper spacer and the spring collar.
7. Hold the rebound adjuster (A, Figure 47) and remove
the fork cap (B) from the adjuster.
8. Remove the spring plate tool and fork spring compres-
sor.
9. Remove the spacers, spring collar and fork spring from
the fork tube.
10. Remove the slider from the vise. Pour out the oil by
pumping the damper rod until the rod moves freely. Check
the oil for contamination, which indicates worn or damaged
parts. Discard the oil after examining it.
11. Remove the Allen screw and washer (Figure 48) at the
bottom of the slider.
12. Insert a small flat-tipped screwdriver under the dust
cover (9, Figure 42), and pry the cover out of the slider. Do

FRONT SUSPENSION AND STEERING

513

14

44

45

FORK ADJUSTER

1. Stopper ring
2. Rebound adjuster
3. Preload adjuster
4. Preload adjuster plate
5. Fork cap

46

47

not damage the slider surface. Remove the cover from the
slider.
13. Insert a small flat-tipped screwdriver under the dust
seal (Figure 49). Pry the seal out of the slider and remove it.
Do not damage the slider surface.
14. Pry the retaining ring out of the groove in the slider and
remove it. See Figure 50.

NOTE

The slider bushing is installed with an inter-
ference fit. When separating the fork tube and
slider, the slider bushing, spacer seal and oil
seal will be removed at the same time.

15. Hold the fork tube and pull the slider downward re-
peatedly so the slider bushing knocks against the fork tube
bushing (Figure 51). As the slider bushing is knocked out
of the slider, it pushes the oil seal and seal spacer out of the
slider. Continue until these components are removed from
the slider.

Inspection

CAUTION

Clean and handle the guide bushings (

Figure

52

) carefully to avoid damaging their coating

material. If there is any metal powder cling-
ing to the guide bushings, clean them with
new fork oil and a nylon brush.

1. Initially clean all of the fork components in solvent.
Make sure any cleaning solvents used will not damage the
rubber parts. Then, clean all components with soap and wa-
ter, and rinse them with clear water. Dry thoroughly.
2. Check the fork tube (A, Figure 53) for bending, nicks,
rust or other damage. Check the fork tube runout with a set
of V-blocks and a dial indicator. Replace the fork tube if
runout exceeds 0.008 in. (0.2 mm).
3. Check the slider (B, Figure 53) for dents or other exte-
rior damage. Check the retaining ring groove (Figure 54) in
the top of the slider for cracks or other damage. Replace the
slider if the groove is cracked or damaged.
4. Check the slider and fork tube bushings (Figure 52) for
severe wear, cracks or damage. The slider bushing was re-
moved with the oil seal. The fork tube bushing should not
be removed unless it is going to be replaced. To replace the
fork tube bushing, perform the following:

a. Expand the bushing slit (Figure 55) using a screw-

driver and slide the bushing off the fork tube.

b. Coat the new bushing with new fork oil.
c. Install the new bushing by expanding the slit using a

screwdriver. Expand the bushing only enough to fit it
over the fork tube.

d. Seat the new bushing into the groove in the fork tube.

5. Replace the Allen bolt and washer if damaged.
6. Make sure the oil passage holes in the damper are open.
If clogged, flush with solvent and dry with compressed air.

514

CHAPTER FOURTEEN

48

49

50

51

7. Check the threads in the bottom of the damper for strip-
ping, cross-threading or sealer residue. If necessary, use a
tap to renew the threads or to remove any deposits.
8. Check the fork spring free length. Replace the fork
spring if the free length is less than 16.02 in. (407 mm).
9. Inspect the outer dust seal(s) (B, Figure 56) for cracks,
weather deterioration or other damage. Damaged dust seals
allow dirt to pass through and damage the oil seal.
10. Replace the fork cap O-ring if leaking or if severe wear
or damage is apparent.
11. Replace any worn or damaged parts.
12. When replacing fork springs, replace the springs as a
set.

Assembly

Refer to Figure 42.

1. Prior to assembly, perform the inspection procedure in
this section to confirm all worn or defective parts have been
repaired or replaced. Clean all parts before assembly.
2. Coat all parts with the specified fork oil (Chapter Three)
before assembly.
3. Insert the fork tube into the slider.

NOTE

The slider bushing, seal spacer and oil seal
are installed into the slider at the same time.
Use a fork seal driver (part No. HD-36583 or
an equvalent). A piece of pipe can also be
used to drive the parts into the slider. When
using a piece of pipe or similar tool do not
damage the slider, oil seal or fork tube. Wrap
both ends of the pipe or tool with duct tape to
prevent it from scratching the fork tube and
tearing the oil seal.

4. Install the slider bushing, seal spacer and oil seal at the
same time. Perform the following:

a. Coat the slider bushing (A, Figure 57) with fork oil.

Slide the bushing down the forktube and rest it against
the slider bore. Make sure the opening in the bushing
faces the side, not the front or rear of the slider.

FRONT SUSPENSION AND STEERING

515

14

52

53

54

55

56

b. Install the seal spacer (B, Figure 57) over the fork

tube with the concave side facing down. Rest the seal
spacer on the slider bushing.

c. Slide a new oil seal (C, Figure 57) over the fork tube

with the closed side facing up. Rest the oil seal on the
seal spacer.

d. Slide the fork seal driver down the fork tube (Figure

58).

e. Drive the bushing, seal spacer and oil seal into the

slider until the retaining ring groove in the slider can
be seen above the top surface of the oil seal.

f. Remove the fork seal driver.

5. Install the retaining ring (Figure 50) into the slider
groove. Make sure the retaining ring is fully seated in the
groove.

6. Slide the dust seal (Figure 49) down the fork tube and
seat it into the top of the slider.

7. If the rebound adjuster was removed from the damper
rod, perform the following:

a. Turn the locknut onto the damper rod until the nut

bottoms.

b. Press the detent spring and ball with your thumb, and

turn the rebound adjuster counterclockwise until it

516

CHAPTER FOURTEEN

57

58

59

60

TIGHTEN

61

backs out to the last click (Figure 59). Turn the re-
bound adjuster clockwise 13 clicks.

c. Thread the rebound adjuster onto the damper rod.

Turn the rod as far as it will go without forcing it. Do
not overtighten the adjuster.

d. Thread the locknut (A, Figure 60) up into the re-

bound adjuster until the locknut is seated against the
rebound adjuster (B).

8. Clamp the fork axle boss at the bottom of the slider in a
vise with soft jaws. Do not clamp the slider at any point
above the fork axle boss.

9. Install the damper into the fork tube.
10. Install the Allen bolt by performing the following:

a. Insert the fork spring into the fork tube so the tightly

coiled end goes down into the slider. Install the fork
cap to tension the spring and hold the damper in
place.

b. Install the washer onto the damper rod Allen bolt.
c. Insert the Allen bolt (Figure 48) through the lower

end of the slider and thread it into the damper.
Tighten the bolt to 22-29 ft.-lb. (30-39 N•m).

d. Remove the fork cap and fork spring.

11. Refer to Table 1 for the fork oil capacity. Pour half of
the quantity into the fork tube. Pump the damper rod slowly
to purge air from the slider and fork tube (Figure 61). Pump
the rod at least ten times.
12. Push the damper rod into the fork tube until it bottoms.
13. Pour the remaining quantity of fork oil into the fork
tube.

NOTE

An oil level-measuring device can be made,
as shown in

Figure 62

. Position the lower

edge of the hose clamp at the specified oil
level distance up from the small diameter
hole. Fill the fork with a few ounces more
than the required amount of oil. Position the
hose clamp on the top edge of the fork tube
and draw out the excess oil. Oil is drawn out
until the level reaches the small diameter
hole. A precise oil level can be achieved with
this simple device.

14. Use an oil gauge (part No. HD-59000A or equivalent)
to adjust the oil to the level specified in Table 1. See Figure
63.
15. Install the fork spring so the end with closer-wound
coils faces the slider.
16. Install one spacer, the spring collar, and the other
spacer into the fork tube. One side of the spacer has sharper
edges than the other one. Make sure the side with the sharp
edge faces the spring collar.

FRONT SUSPENSION AND STEERING

517

14

62

Approximately 1 in. (25 mm)

Specified

fork oil

level

Hole diameter
approx. 1/8 in. (3 mm)

Small diameter hose clamp

Oil

su

cti

on

gu

n

63

Fork oil level

17. Install the fork spring compressor (A, Figure 46) onto
the spring collar. Tighten the screws on the compressor so
they engage the holes on the spring collar.
18. Use the tool to compress the spring and have an assis-
tant install the spring plate (B, Figure 46) between the up-
per spacer and the spring collar.
19. Install the fork cap (B, Figure 47) onto the rebound ad-
juster (A). Tighten the fork cap to 22-29 ft.-lb. (30-39 N•m).
20. Remove the spring plate and fork spring compressor.
Turn the fork cap into the fork tube. Tighten the fork cap to
11-22 ft.-lb. (15-30 N•m).
21. Install the preload adjuster plate (4, Figure 45).
22. Install a new O-ring onto the preload adjuster (3, Fig-
ure 45). Lubricate the O-ring with fork oil, and install the
preload adjuster.
23. Install the stopper ring.
24. Install the dust cover (Figure 64) as follows:

a. Slide the dust cover down the fork tube and rest it

against the top of the slider.

b. Slide one of the discarded oil seals down the fork

tube and rest it against the dust cover.

c. Use the same fork seal driver used in Step 4 and care-

fully drive the old dust cover onto the top of the slider
as shown in Figure 64.

d. Remove the driver and old oil seal.

25. Adjust the spring, compression damping and rebound
damping (Chapter Three).

STEERING HEAD AND STEM

The fork stem extends from the lower triple clamp into

the frame steering head. The lower portion of the steering
head rests on a tapered roller bearing located at the bottom
of the fork stem. The upper end of the fork stem rides in a
tapered roller bearing that seats in the upper portion of the
steering head. Both bearings seat against races pressed into
the steering head. Dust shields are used at both bearing ar-
eas to protect bearings from dust and other contaminants.

Removal

Refer to Figure 65 or Figure 66.

518

CHAPTER FOURTEEN

64

65

STEERING ASSEMBLY

(1986-1987 MODELS)

1. Nut
2. Pinch bolt
3. Upper fork bracket
4. Screw
5. Screw
6. Upper bearing shield
7. Bearing
8. Upper bearing race
9. Frame

10. Lower bearing race
11. Bearing
12. Dust shield
13. Steering stem and bracket
14. Lower fork bracket

FRONT SUSPENSION AND STEERING

519

14

66

STEERING ASSEMBLY (1988-2003 MODELS)

1. Cap (1991-2003 models)
2. Steering stem bolt
3. Washer
4. Upper fork bracket
5. Pinch bolt
6. Dust shield
7. Upper bearing
8. Upper bearing racer
9. Frame neck

10. Lower bearing race
11. Lower bearing
12. Dust shield
13. Steering stem/lower fork bracket
14. Upper fork tube pinch bolt
15. Lower fork tube pinch bolt
16. Lower fork bracket

NOTE

Although not necessary, it is advisable to re-
move the fuel tank as described in Chapter
Ten or Chapter Eleven. Otherwise, cover it
with suitable material.

1. Remove the headlight (Chapter Twelve).
2. Remove the front fork as described in this chapter.
3. On models so equipped, disconnect the speedometer
and tachometer cables from the instruments.
4A. On 1998-2003 models, remove the brake hose bracket
at the bottom of the fork stem bracket (Figure 67). Do not
disconnect the brake hose connection.
4B. On 1986-1987 models, detach the brake hose bracket
on the upper fork bracket. Do not disconnect the brake hose
connection.

NOTE

If it is not necessary to remove the handlebar,
the handlebar can be removed along with the
upper fork bracket. If necessary, remove the
handlebar as described in this chapter.

5. On 1991-2003 models, unscrew the bolt cap (Figure 68)
and remove it. See Figure 69.
6A. On 1986-1987 models, remove the fork stem end nut
(Figure 70).
6B. Remove the steering stem bolt (A, Figure 71) and washer.

NOTE

Make sure the steering stem lower fork
bracket to keep it from falling out once the
pinch bolt is loosened.

7. Loosen the pinch bolt (B, Figure 71) and lift the upper
fork bracket (C) off the steering stem. Set the bracket aside
with the cables attached.
8. Lower the fork stem assembly out of the steering head
and remove it.
9. Remove the upper dust cover (Figure 72) and bearing
(Figure 73).
10. Inspect the fork stem and bearing assembly as de-
scribed in this chapter.

Inspection

The bearing races (Figure 74) are pressed into the steer-

ing head. Do not remove the bearing races unless they re-
quire replacement.

Use wheel bearing grease to pack bearings and races

when performing the following steps.
1. Wipe the bearing races with a solvent soaked rag and
then dry with compressed air or a lint-free cloth. Check the
races in the steering head for pitting, scratches, galling or
severe wear. If any of these conditions exist, replace the
races as described in this chapter. If the races are in good
condition, wipe each race with grease.

520

CHAPTER FOURTEEN

67

68

69

70

2. Clean the bearings in solvent to remove all of the old
grease. Blow the bearing dry with compressed air, making
sure not to allow the air jet to spin the bearing. Do not remove
the lower bearing from the fork stem unless replacement is re-
quired; clean the bearing together with the steering stem.
3. After the bearings are dry, hold the inner race with one
hand and turn the outer race with your other hand. Turn the
bearing slowly, checking for roughness, looseness, trapped
dirt or grit. Check the bearing (Figure 75) for pitting,
scratches or visible damage. If the bearings are worn, check
the dust covers for wear or damage or for improper bearing
lubrication. Replace the bearing if necessary. Pack it with
grease and wrap it with wax paper until it can be reinstalled.
Do not store the bearings for any length of time without
lubricating them or they will rust.
4. Check the steering stem for cracks or damage. Check the
threads at the top of the stem for strippage or damage.
Check the steering stem bolt or nut by threading it into the
steering stem; make sure the bolt or nut threads easily with
no roughness. If necessary, clean the threads carefully with
a brush and solvent or use a tap or die of the correct thread
type and size.
5. Worn or damaged parts should be replaced. When dis-
carding a bearing, both bearings and their races should be
replaced at the same time. Replace bearing races as de-
scribed in this chapter.
6. Replace the lower steering stem bearing and dust cover
as described in this chapter.
7. Check for broken welds on the frame around the steering
head. If any are found, have them repaired by a frame shop.

Installation

1. Make sure the steering head bearing races are properly
seated as described in

Steering Head Bearing

in this chap-

ter..
2. Wipe the bearing races with a clean lint-free cloth. Then
lubricate each race with bearing grease.
3. Pack the upper and lower bearings with bearing grease.
The lower bearing and lower dust shield should be installed
on the steering stem prior to installing the steering stem in
the steering head. If necessary, install the lower bearing as
described in this chapter.

FRONT SUSPENSION AND STEERING

521

14

71

72

73

74

75

4. Insert the steering stem into the frame steering head and
hold it firmly in place.
5. Install the upper bearing around the fork stem and seat it
into the upper race. Install the upper dust shield.
6. Install the upper fork bracket (C, Figure 71) over the
steering stem.
7. Install the washer and the steering stem bolt (A, Figure
71). Tighten the bolt hand-tight only.
8. Install the front fork as described in this chapter.
9. Tighten the steering stem bolt (A, Figure 71) until the
steering stem can be turned from side to side with no notice-
able axial or lateral bearing play. When the play feels cor-
rect, tighten the fork stem pinch bolt (B, Figure 71)
securely on 1986-1987 models or to 30 ft.-lb. (41 N•m) on
1988-2003 models.

CAUTION

Do not overtighten the steering stem bolt or
the bearings and races may be damaged. Fi-
nal adjustment of the fork stem will take place
after the front wheel has been installed on the
motorcycle.

10. Install the brake hose bracket onto the lower fork
bracket and tighten the mounting bolt (Figure 67) securely.
11. Install the front wheel (Chapter Thirteen).
12. Adjust the steering play as described in

Steering Play

Adjustment

in this chapter.

STEERING HEAD BEARING

Whenever the steering stem and bearings are removed

from the steering head, cover the steering head with a cloth
to protect the bearing races from accidental damage. If a
race is damaged, the bearing and race must be replaced as a
set. Because the bearing races are pressed into place, do not
remove them unless they require replacement.

Upper and Lower Bearing Race Replacement

The upper and lower bearing races (Figure 74) are

pressed into the frame steering head. Both races are identi-
cal and can be purchased separately from the bearing. If
bearing replacement is required, purchase the bearing and
race as a set.
1. To remove a race, insert an aluminum or brass rod into
the steering head and carefully tap the race out from the in-
side (Figure 76). Tap around the race so that neither the
race nor the steering head are bent.
2. Clean the steering head with solvent and dry thoroughly.
3A. The bearing races can be installed using a head bear-
ing race installation tool (part No. HD-39302 or equiva-
lent). Follow the manfacturer’s instructions for using the
tool.
3B. If a head bearing race installation tool is not available,
install the bearing races as follows:

a. Clean the race thoroughly before installing it.

b. Align the upper race with the frame steering head and

tap it slowly and squarely in place with a block of
wood, a suitable socket or bearing driver, making
sure not to contact the bearing race tapered surface.
See Figure 77. If an old race is available, grind its
outside rim so that it is a slip fit in the steering head,
then use it to drive the new race into place. Drive the
race into the steering head until it bottoms on the bore
shoulder.

c. Repeat to install the lower race into the steering head.

522

CHAPTER FOURTEEN

76

77

Wood block

Race

Head tube

4. Lubricate the bearing races with wheel bearing grease.

Fork Stem Lower Bearing Replacement

Do not remove the fork stem lower bearing (Figure 78,

typical) unless it is going to be replaced with a new bearing.
Do not reinstall a lower bearing that has been removed, as it

is no longer true to alignment. When replacing the lower
bearing, install a new lower dust shield.

WARNING

Safety glasses and insulated gloves must be
worn when removing the inner race.

1. Using a chisel, break the bearing cage and rollers from
the inner race. When the bearing cage and rollers are free,
the inner race on the fork stem is exposed. To remove the
inner race, heat the race with a torch until it expands enough
to slide or drop off the fork stem. Remove and discard the
dust cover after removing the bearing.
2. Clean the fork stem with solvent and dry thoroughly.
3. Pack the new bearing with grease before installing it.
4. Slide a new dust shield onto the fork stem so it bottoms
on the lower bracket.
5. Align the new bearing with the fork stem and press or
drive it onto the fork stem until it bottoms. When installing
the bearing onto the fork stem, a bearing driver must be
used against the inner bearing race (Figure 79). Do not in-
stall the bearing by driving against the outer bearing race.

STEERING PLAY ADJUSTMENT

The steering play should be checked periodically and

anytime the steering stem assembly has been removed and
installed.
1. Support the motorcycle so that the front wheel clears the
ground.
2. Remove the windshield, if used, and all other accessory
weight from the handlebar and front forks. If any control
cable affects handlebar movement, disconnect it.
3. Apply a strip of masking tape across the front end of the
front fender. Draw a vertical line across the tape at the cen-
ter of the fender. Then draw two lines on each side of the
centerline, 1 inch apart from each other. See Figure 80.
4. Turn the handlebar so that the front wheel points straight
ahead.
5. Place a pointer on a stand and then center the pointer so
that its tip points to the center of the fender (tape mark)
when the wheel points straight ahead.
6. Lightly push the fender towards the right side until the
front end starts to turn by itself. Mark this point on the tape.
7. Repeat Step 6 for the left side.
8. Measure the distance between the two marks on the
tape. For proper bearing adjustment, the distance should be
1-2 in. (25.4-50.8 mm). If the distance is incorrect, perform
Step 9.
9. Adjust steering play as follows:

a. Loosen the lower fork tube pinch bolts (Figure 81).
b. On 1991-2003 models, unscrew and remove the bolt

cap (Figure 69).

c. Loosen the fork stem pinch bolt (A, Figure 82).
d. If the distance between the two marks is less than 1

in. (25.4 mm), tighten the steering stem nut (Figure
70) or bolt (B, Figure 82).

FRONT SUSPENSION AND STEERING

523

14

78

79

Bearing driver

Bearing

80

Center fender mark

Masking tape (tape to front fender)

“O” mark

e. If the distance between the two marks is more than 2

in. (50.8 mm), loosen the steering stem nut (Figure
70) or bolt (B, Figure 82).

f. Repeat Steps 6 and 7 to measure steering play, con-

tinue until the distance between the two marks is
within 1-2 in. (25.4-50.8 mm).

10. When steering play adjustment is correct, perform the
following:

a. Tighten the fork stem pinch bolt (A, Figure 82) se-

curely on 1986-1987 models or to 30 ft.-lb. (41 N•m)
on 1988-2003 models.

b. Tighten the lower bracket pinch bolt (Figure 81) to

30 ft.-lb. (41 N•m).

c. On 1991-2003 models, install and tighten the bolt cap

(Figure 69) securely.

11. Reinstall all parts previously removed.

524

CHAPTER FOURTEEN

Table 1 FRONT FORK OIL* CAPACITY

Wet

Dry

oz.

ml

oz.

ml

1986-1987 models

5.4

160

6.4

189

1988-1991 models

9.0

266

10.2

302

1992-1998 models

883H models

10.7

316

12.1

358

All other models

9.0

266

10.2

302

1999-2003 models

9.0

266

10.2

302

*Harley-Davidson Type E or equivalent.

Table 2 FRONT FORK SPECIFICATIONS (XL1200S MODELS)

in.

mm

Fork tube runout

0.008

0.2

Fork spring free length

16.02

407

Fork oil level (below top of fork tube)

5.6

142

Table 3 FRONT SUSPENSION TORQUE SPECIFICATIONS

ft.-lb.

in.-lb.

N•m

Brake hose clamp screws

–

30-40

3-5

Fork cap to rebound

adjuster (1200S models)

22-29

–

30-39

Fork cap to fork tube

(1200S models)*

11-22

–

15-30

Fork lower bracket pinch bolt

30

–

41

Fork slider Allen bolt

(1200S models)

22-29

–

30-39

(continued)

81

82