Harley Davidson FXD DYNA 2019. Service repair Manual and Wiring Diagrams — page 21
400
CHAPTER NINE
7. Press the upper bead into the rim opposite the
valve stem (Figure 61). Pry the bead into the rim on
61
both sides of the initial point with both hands and
work around the rim to the valve stem (Figure 62).
If the tire wants to pull up on one side, either use a
tire iron or one knee to hold the tire in place. The
last few inches are usually the toughest to install.
Continue to push the tire into the rim by hand.
Re-lubricate the bead if necessary. If the tire bead
wants to pull out from under the rim use both knees
to hold the tire in place. If necessary, use a tire iron
for the last few inches.
8. Bounce the wheel several times, rotating it each
time. This will force the tire bead against the rim
62
flanges. After the tire beads are in contact with the
rim, inflate the tire to seat the beads.
9. Place an inflatable band around the circumference
of the tire. Slowly inflate the band until the tire beads
are pressed against the rim. Inflate the tire enough to
make it seat, deflate the band and remove it.
WARNING
In the next step, never exceed 40 psi
(276 kPa) inflation pressure as the tire
could burst, causing severe injury.
Never stand directly over a tire while
inflating it.
63
10. After inflating the tire, check to see that the
beads are fully seated and that the rim lines are the
same distance from the rim all the way around the
tire. If the beads will not seat, deflate the tire and lu-
bricate the rim and beads with soapy water.
11. Re-inflate the tire to the pressure listed in Table
4. Install the valve stem cap.
12. Balance the wheel as described in this chapter.
13A. Install the front wheel as described in this chapter.
13B. Install the rear wheel as described in this chapter.
TIRE REPAIRS
Tubeless tires have TUBELESS molded into the
sidewall and the rims have SUITABLE FOR
NOTE
TUBELESS TIRES or equivalent stamped or cast
Changing or patching on the road is
on them.
very difficult. A can of pressurized tire
If the tire is punctured, it must be removed from
inflator and sealer may inflate the tire
the rim to inspect the inside of the tire and to apply a
and seal the hole, although this is only
combination plug/patch from inside the tire (Figure
a temporary fix.
63). Never attempt to repair a tubeless motorcycle
tire using a plug or cord patch applied from outside
WARNING
Do not install an inner tube inside a
the tire.
tubeless tire. The tube will cause an
After repairing a tubeless tire, don’t exceed 50
abnormal heat buildup in the tire.
mph (80 km/h) for the first 24 hours.
WHEELS, HUBS AND TIRES
401
Repair
64
Do not rely on a plug or cord patch applied from
outside the tire. Use a combination plug/patch ap-
plied from inside the tire (Figure 63).
1. Remove the tire from the wheel rim as described
in this chapter.
2. Inspect the rim inner flange. Smooth any
scratches on the sealing surface with emery cloth. If
a scratch is deeper than 0.5 mm (0.020 in.), the
Gauge
wheel should be replaced.
3. Inspect the tire inside and out. Replace a tire if
any of the following is found:
a. A puncture larger than 3 mm (1/8 in) diameter.
b. A punctured or damaged side wall.
c. More than 2 punctures in the tire.
4. Apply the plug/patch following the manufac-
turer’s instructions with the patch kit.
Tire Runout
Tire lateral
runout
Check the tires for excessive lateral and radial
9
runout after a wheel has been mounted or if the mo-
torcycle developed a wobble that cannot be traced
to another component. Mount the wheels on their
axles when making the following checks.
1. Lateral runout: This procedure will check the tire
65
for excessive side-to-side play. Perform the following:
a. Position a fixed pointer next to the tire sidewall
as shown in Figure 64. Position the pointer tip
so that it is not directly in line with the molded
tire logo or any other raised surface.
b. Rotate the tire and measure lateral runout.
c. The lateral runout must not exceed 0.080 in.
(2.03 mm). If runout is excessive, remove the
tire from the wheel and recheck the wheel’s
lateral runout as described in this chapter. If the
runout is excessive, the wheel must be trued
(laced wheels) or replaced (alloy wheels). If
wheel runout is correct, the tire runout is ex-
cessive and the tire must be replaced.
2. Radial runout: This procedure will check the tire
for excessive up-and-down play. Perform the follow-
ing:
a. Position a fixed pointer at the center bottom
Tire radial
of the tire tread as shown in Figure 65.
runout
Gauge
b. Rotate the tire and measure the amount of ra-
dial runout.
c. The radial runout must not exceed 0.090 in.
(2.29 mm). If runout is excessive, remove the
402
CHAPTER NINE
tire from the wheel and recheck the wheel’s
radial runout as described in this chapter. If
66
the runout is excessive, true or replace the
wheel. If wheel runout is correct, the tire run-
out is excessive and the tire must be replaced.
VEHICLE ALIGNMENT
This procedure checks the alignment of the rear
axle with the swing arm pivot shaft. It also checks
the engine stabilizer adjustment that aligns the en-
gine in the frame. These checks determine the con-
dition and alignment of the components that hold
the motorcycle together: steering stem, front axle,
67
engine, swing arm pivot shaft and rear axle. If any
of these items are out of alignment, the motorcycle
will not handle properly. Bad handling will increase
the motorcycle’s vibration level while reducing its
overall performance and driveability.
Preliminary Inspection
Before checking vehicle alignment, make the fol-
lowing checks to spot problems caused from normal
wear. Adjust, repair or replace any component as re-
quired.
68
1. The engine stabilizer (Figure 66), mounted be-
tween the cylinder heads and upper frame tube,
Grommet
aligns the engine in the frame. Check the engine sta-
bilizer every 10,000 miles (16,000 km) for loose or
damaged parts. To service or replace the engine sta-
1-1/4 in.
bilizer, refer to Chapter Four. To adjust the engine
(32 mm)
10 in.
stabilizer, perform the Alignment procedure in this
(254 mm)
section.
2. Check the steering head bearing adjustment as
described under Steering Play Adjustment in Chap-
ter Ten.
3. Check the runout of each wheel as described in
this chapter.
2. A rear axle alignment tool is made of 1/8
in. (3.2
mm) welding rod 11 in. (280 mm) long, as shown in
Figure 68. The grommets can be purchased from
Special Tools
electronic supply and hardware stores. To use this tool
accurately, the grommet must be a snug fit on the tool.
The following tools are required to check vehicle
alignment:
1. An inclinometer (Figure 67) checks the vertical
Alignment
position (angle) of the brake discs when checking
engine alignment. This tool, which has a magnetic
Each alignment step (check and adjustment) af-
base and a 360-degree dial, can be purchased from
fects the next one. Work carefully and accurately
most tool and hardware stores.
when performing the following steps.
WHEELS, HUBS AND TIRES
403
Axle alignment is correct if the two measurements
69
are within 0.032 in. (0.8 mm) of each other.
6. If the alignment is incorrect, perform the Final
Drive Belt Adjustment procedure in Chapter Three.
When the drive belt adjustment is correct, continue
with Step 7.
NOTE
The following steps must be performed
with the rear wheel off the ground.
7. Remove the bolt (Figure 70) securing the stabi-
lizer link to the engine mounting bracket. Do not re-
move the bolt securing the stabilizer link to the
frame.
70
8. Place the inclinometer on the front brake disc.
Position the front wheel so that the brake disc is ver-
Locknut
Front
tical (90°). This position must be maintained when
performing Steps 9 and 10.
9. Align the stabilizer link hole with the engine
mounting bracket and install the stabilizer link bolt
(Figure 70). Do not force the bolt into position.
Note the following:
Adjust nut
9
a. If the holes do not align, adjust the stabilizer,
starting with Step 10.
Stabilizer link
b. If the holes align, go to Step 14.
10. Loosen the stabilizer locknut. Then adjust the
stabilizer link until the bolt can be installed without
Engine mounting bracket
moving the engine. Tighten the locknut when the
adjustment is correct.
11. Now put the inclinometer on the rear brake disc
1.
Perform all of the checks listed under Prelimi-
and compare its position with the front brake disc. If
nary Inspection in this section. When all of the
the readings are not within 1° of each other, con-
checks are within the specifications, continue with
tinue with Step 12.
Step 2. If the motorcycle has been involved in a
12. Readjust the stabilizer link (Step 10) until the
crash, refer frame alignment to a Harley-Davidson
rear brake disc is within 1° of the front brake disc.
dealership or motorcycle frame alignment special-
Note the following:
ist.
a. If the adjustment cannot bring the brake discs
2. The exhaust system must be installed on the mo-
within 1° of each other, inspect the swing
torcycle when performing the following steps.
arm, frame, steering head and front forks for
damage. If necessary, take the motorcycle to a
3. Support the motorcycle with the rear wheel off
Harley-Davidson dealership for further in-
the ground.
spection.
4. Insert the alignment tool (Figure 68) into one of
b. If the adjustment can bring the brake disc an-
the swing arm index holes. Then hold it parallel
gle to within 1°, but it takes more than five
with the rear axle and slide the grommet along the
turns of the stabilizer link to do so, perform
tool until it is centered with the axle (Figure 69).
the chassis inspections described in substep a.
5. Remove the alignment tool without disturbing
If a problem can not be found with a chassis
the position of the grommet and insert the tool into
component, go to Step 13.
the opposite side of the swing arm. Compare the
c. If the adjustment cannot bring the brake discs
axle center point with the position of the grommet.
within 1° and it takes less than five turns of
404
CHAPTER NINE
the stabilizer link, tighten the stabilizer
b. Lower the motorcycle so that both wheels are
locknut and go to Step 14.
on the ground.
c. With the transmission in NEUTRAL, start the
13. These steps center the frame and engine
motorcycle and let it idle for approximately 5
mounts. Perform this procedure if it takes more than
seconds. Then shut the engine off.
five turns to align the brake discs. Read through the
d. Tighten all of the isolator mounting bolts to
substeps and then follow these steps:
25 ft.-lb. (34 N•m).
a. Loosen, but do not remove, the front and rear
14. Tighten the stabilizer link-to-engine mounting
engine isolator mounting bolts.
bracket bolt securely.
Table 1 WHEEL SPECIFICATIONS
In.
mm
Wheel runout (maximum)
Laced wheels
Lateral and radial
0.31
0.79
Cast wheels
Lateral
0.040
1.02
Radial
0.030
0.76
End play (1999)
Front and rear
0.002-0.006
0.05-0.15
Table 2 WHEEL TORQUE SPECIFICATIONS
Item
ft.-lb.
in.-lb.
N·m
Front axle nut
50-55
-
68-75
Front axle pinch bolt nut
except FXDWG
25-30
-
34-41
Front fork slider cap nuts
-
60-132
7-15
Front brake caliper
mounting bolt
28-38
-
38-52
Front fender nuts
FXDWG
15-21
-
20-28
All models
except FXDWG
-
120-168
14-19
Driven sprocket bolts
Laced wheel
45-55
-
61-75
Cast wheel
55-65
-
75-88
Rear axle nut
60-65
-
81-88
Rear wheel belt
sprocket screws
Laced wheel
45-55
-
61-75
Cast wheel
55-65
-
75-88
Brake disc bolts
Front wheel
16-24
-
22-33
Rear wheel
30-45
-
41-61
Spoke nipples
-
40-50
4-6
Valve stem nut
-
12-15
1-2
WHEELS, HUBS AND TIRES
405
Table 3 FRONT AND REAR WHEEL BEARING SPACER SHIMS (1999)
Thickness
Part No.
In. (mm)
43290-82
0.030-0.033 (0.76-0.84)
43291-82
0.015-0.017 (0.38-0.43)
43292-82
0.0075-0.0085 (0.190-0.216)
43293-82
0.0035-0.0045 (0.089-0.114)
43294-82
0.0015-0.0025 (0.038-0.064)
Table 4 TIRE INFLATION PRESSURE (COLD)*
Model
kPa
PSI
Front wheels
Rider only
207
30
Rider and one passenger
207
30
Rear wheels
Rider only
248
36
Rider and one passenger
276
40
*Tire pressure for factory equipped tires. After market tires may require different inflation pressure.
9
CHAPTER TEN
FRONT SUSPENSION AND STEERING
This chapter covers the handlebar, steering head
dental scratches or dents when
and front fork assemblies.
removing the handlebar.
Tables 1-3 are at the end of the chapter.
NOTE
Before removing the handlebar, make
HANDLEBAR
a drawing of the clutch and throttle
cable routing from the handlebar and
Removal/Installation
through the frame. This information
will prove helpful when reinstalling
Refer to Figure 1.
the handlebar and connecting the ca-
1. Support the motorcycle with the front wheel off
bles.
the ground. See Motorcycle Stands in Chapter Nine.
2. On the right side of the handlebar, perform the
NOTE
following:
Cover the fuel tank with a heavy cloth
a. Remove the front turn signal (A, Figure 2)
or plastic tarp to protect it from acci-
from the master cylinder.
FRONT SUSPENSION AND STEERING
407
1
HANDLEBAR
3
4
10
b. Unscrew and remove the mirror (B, Figure
1. Allen bolt
2. Washer
2).
3. Holder
c. Remove the screws securing the master cylin-
4. Handlebar
der (C, Figure 2). Do not disconnect the hy-
5. Lower clamp
draulic brake line.
6. Cup washer
7. Rubber bushing
d. Loosen the throttle housing
(D, Figure 2)
8. Collar
screws and slide the assembly off the handlebar.
9. Washer
3. On the left side of the handlebar, perform the fol-
10. Bolt
lowing:
11. Washer
12. Ground cable
a. Remove the front turn signal (A, Figure 3)
from the master cylinder.
b. Unscrew and remove the mirror (B, Figure
3).
c. Remove the screws securing the left side
2
switch assembly together (C, Figure 3) and
separate the housing halves.
d. Remove the clutch lever clamp (D, Figure 3)
mounting screws and separate the clamp
halves.
4. Disconnect or remove any wiring harness
clamps at the handlebar.
5A. On FXD, FXDS-CON, FXDX and FXDXT
models, remove the two front handlebar clamp bolts
(A, Figure 4) and washers. Then set the instrument
408
CHAPTER TEN
housing forward (B) so it does not scratch the han-
dlebar clamp.
5
5B. On all other models, remove the two front han-
dlebar clamp bolts (A, Figure 4) and washers.
6. Remove the two rear clamp bolts (C, Figure 4),
then remove the holder (D) and handlebar (E).
7. Install the handlebar by reversing these steps
while noting the following:
a. Check the knurled rings on the handlebar for
galling and bits of aluminum. Clean the
knurled section with a wire brush.
b. Check the handlebar for cracks, bends or
other damage. Replace the handlebar if nec-
essary. Do not attempt to repair it.
6
FORK INSTALLATION
c. Thoroughly clean the clamp halves of all resi-
due.
d. After installing the handlebar, reposition the
handlebar while sitting on the motorcycle.
0.42-0.50 in.
Cap bolt
e. Tighten the handlebar clamp bolts securely.
(10.7-12.7 mm)
f. Adjust the mirrors.
FRONT FORK
(FXD, FXDL, FXDS-CON, FXDWG,
FXDP AND 1999 FXDX)
Bracket
Fork tube
Front Fork Service
Before assuming that a fork is internally malfunc-
tioning, drain the front fork oil and refill with the
proper type and quantity of fork oil as described in
5.
On FXDWG models, remove the fork tube cap,
Chapter Three. If there is still a problem, such as
spacer and oil seal from the top of one fork tube.
poor damping or a tendency to bottom or top out,
6. Loosen the upper fork bracket pinch bolt (A,
follow the service procedures in this section.
Figure 5).
To simplify fork service and to prevent the mix-
7A. On FXDWG models, if the forks are going to be
ing of parts, remove, service and install the fork legs
disassembled, loosen the fork tube plug.
individually.
7B. On all models other than FXDWG models, if
the forks are going to be disassembled, loosen the
fork cap (B, Figure 5).
Removal
8. Loosen the lower fork bracket pinch bolt and
slide the fork tube out of the fork brackets. It may be
1. Support the motorcycle with the front wheel off
necessary to rotate the fork tube slightly while pull-
the ground. See Motorcycle Stands in Chapter Nine.
ing it down and out. Remove the fork assembly and
2. Remove the front fender and front wheel as de-
take it to the workbench for service. If the fork is not
scribed in Chapter Nine.
going to be serviced, wrap it in a bath towel or blan-
3. If both fork tube assemblies are going to be re-
ket to protect the surface from damage.
moved, mark them with an R (right side) and L (left
side) so the assemblies will be reinstalled on the
NOTE
correct side.
Identify the fork tubes so they will be
4. On FXDX-CON models, remove the windshield
installed on the correct side.
and its mounting clamps as described in Chapter
Thirteen.
9. Repeat for the other fork assembly.
FRONT SUSPENSION AND STEERING
409
Installation
7
FRONT FORK (FXD, FXDL,
FXDS-CON, FXDP,
1. Clean off any corrosion or dirt on the upper and
1999 FXDX)
lower fork bracket receptacles.
2A. On FXD, FXDL, FXDS-CON and 1999 FXDX
models, install each fork tube so that the tube ex-
tends 0.42-0.50 in. (10.7-12.7 mm) above the upper
fork bracket as shown in Figure 6.
2B. On FXDWG models, perform the following:
a. Install a fork tube through the fork brackets
and tighten the lower pinch bolt.
b. Position the fork tube so that one flat on the
fork tube plug faces toward the steering stem.
Hold the fork in this position and install the
new oil seal, washer and the fork tube top cap.
Repeat for the other fork tube.
c. Position the fork tube so it is flush with the
top surface of the upper fork bracket.
3. Tighten the lower fork bracket pinch bolt to the
specification in Table 1.
4. If loose, tighten the fork cap (B, Figure 5) se-
curely.
5. Tighten the upper fork bracket pinch bolt (A,
Figure 5) to the specification in Table 1.
6. On FXDWG models, tighten the fork tube cap
10
securely.
7. Install the front fender and front wheel as de-
scribed in Chapter Nine.
8. Apply the front brake and pump the front fork
several times to seat the fork and front wheel.
Disassembly
Refer to Figure 7 or Figure 8.
1. Clamp the fork slider’s front axle boss in a vise
with soft jaws. Do not clamp the slider at any point
above the fork axle boss in a vise.
1.
Center plug
13.
Retainer ring
NOTE
2.
Top cap
14.
Oil seal
Loosen the bottom Allen bolt before
3.
O-ring
15.
Oil seal spacer
removing the fork cap and spring.
4.
Spring
16.
Slider bushing
Leaving the cap on provides spring
5.
Piston ring
17.
Oil lock piece
tension against the damper rod. This
6. Piston ring
18.
Slider
prevents the damper rod from turning
7. Damper rod
19.
Drain screw
8. Rebound spring
20.
Clap bolt
when loosening the Allen bolt.
9. Fork tube
21.
Nut
10. Fork tube
22.
Lockwasher
2. Loosen the Allen bolt from the bottom of the
bushing
23.
Washer
slider. Do not remove it at this time, as fork oil will
11. Dust seal cover
24.
Washer
drain out.
12. Dust seal
25.
Allen bolt
3A. On all models except FXDWG, if the fork top
cap was not loosened during removal, hold the fork
410
CHAPTER TEN
tube in a vise with soft jaws and loosen the fork top
cap.
8
FRONT FORK (FXDWG)
3B. On FXDWG models, if the fork top plug was
not loosened during removal, hold the fork tube in a
vise with soft jaws and loosen the fork top plug.
WARNING
Be careful when removing the top cap,
or top plug, as the spring is under
pressure. Protect eyes and face ac-
cordingly.
4. With the fork assembly vertical, remove the fork
top cap, or top plug, from the top of the fork tube.
5. Remove the spring from the fork tube.
6. Remove the fork tube from the vise and pour the
oil into a drain pan. Pump the fork several times by
hand to expel most of the remaining oil.
7A. On all models except FXDWG, remove the dust
seal cover from the slider. Insert a small flat-tipped
screwdriver under the dust seal (Figure 9) and care-
fully pry the dust seal out of the slider and remove it.
7B. On FXDWG models, insert a small flat-tipped
screwdriver under the dust cover and carefully pry
the dust cover out of the slider and remove it.
8. Pry the retaining ring (Figure 10) out of the
groove in the slider and remove it.
9. Remove the Allen bolt and washer (Figure 11)
at the bottom of the slider.
10. There is an interference fit between the bushing
in the fork slider and the bushing on the fork tube. In
order to remove the fork tube from the slider, pull
hard on the fork tube using quick in-and-out strokes
(Figure 12). Doing so will withdraw the bushing
and the oil seal from the slider.
NOTE
1.
Top cap
15.
Oil seal spacer
It may be necessary to slightly heat
2.
Spacer
16.
Slider bushing
the area on the slider around the oil
3.
Oil seal
17.
Oil lock piece
seal prior to removal. Use a rag
4.
Fork tube plug
18.
Slider
soaked in hot water; do not apply a
5.
O-ring
19.
Washer (damper
flame directly to the fork slider.
6.
Spring
rod)
7.
Piston ring
20.
Allen bolt
11. Withdraw the fork tube from the slider.
8.
Damper rod
(damper rod)
9.
Rebound spring
21.
Axle cap
10.
Fork tube
22.
Stud
NOTE
11.
Fork tube
23.
Drain screw
Do not remove the fork tube bushing
bushing
24.
Washer
unless it is going to be replaced. In-
12.
Dust seal cover
25.
Washer
spect it as described in this chapter.
13.
Retainer ring
26.
Lockwasher
14.
Oil seal
27.
Nut
12. Remove the oil lock piece (Figure 13) from the
damper rod.
FRONT SUSPENSION AND STEERING
411
9
13
10
14
10
11
15
13. Remove the damper rod and rebound spring
12
(Figure 14) from the fork tube.
Inspection
Replace any worn or damaged parts.
1. Thoroughly clean all parts in solvent and dry
them. Check the fork tube for signs of wear or
scratches.
2. Check the fork tube (A, Figure 15) for bending,
nicks, rust or other damage. Place the fork tube on a
412
CHAPTER TEN
16
17
set of V-blocks and check runout with a dial indica-
tor. If the special tools are not available, roll the fork
18
tube on a large plate glass or other flat surface.
Specifications for runout are not available.
3. Check the slider (B, Figure 15) for dents or other
exterior damage. Check the retaining ring groove
(Figure 16) in the top of the slider for cracks or
other damage.
4. Check the slider and fork tube bushings for ex-
cessive wear, cracks or damage.
5. To remove the fork tube bushing, perform the
following:
a. Expand the bushing slit (Figure 17) with a
screwdriver and then slide the bushing off the
fork tube.
19
b. Coat the new bushing with new fork oil.
c. Install the new bushing by expanding the slit
with a screwdriver.
d. Seat the new bushing into the fork tube
groove.
6. Check the damper rod piston rings (Figure 18)
for excessive wear, cracks or other damage. If nec-
essary, replace both rings as a set.
7. Check the damper rod for straightness with a set
of V-blocks and a dial indicator (Figure 19) or by
rolling it on a piece of plate glass. Service limit
specifications for runout are not available. If the
damper rod is not straight, replace it.
20
8. Make sure the oil passage holes in the damper
rod (Figure 20) are open. If clogged, flush with sol-
vent and dry with compressed air.
9. Check the threads in the bottom of the damper
rod for stripping, cross-threading or sealer residue.
Use a tap to true up the threads and to remove sealer
deposits.
10. Check the damper rod rebound spring and the
fork spring for wear or damage. Service limit speci-
fications for spring free length are not available.
FRONT SUSPENSION AND STEERING
413
21
25
11. Replace the oil seals (A, Figure 21) whenever
22
they are removed. Always replace both oil seals as a
set.
12. Inspect the dust seals (B, Figure 21) or dust
covers, for cracks, deterioration or other damage. A
damaged dust seal, or dust cover, will allow dirt to
pass through and damage the oil seal.
13. Replace the fork top cap, fork tube plug, or
O-ring if leaking or if wear or damage is apparent.
Assembly
10
1. Coat all parts with Harley-Davidson Type E
Fork Oil, or an equivalent, fork oil before assembly.
23
2. Install the rebound spring onto the damper rod
(Figure 22) and slide the damper rod into the fork
tube until it extends out the end of the fork tube.
3. Install the oil lock piece (Figure 23) onto the end
of the damper rod.
4. Temporarily install the fork spring (A, Figure
24) into the fork tube so that the tapered side of the
spring faces down toward the damper rod.
5A. On all models except FXDWG, install the fork
top cap (B, Figure 24), screw it into place to hold
the damper rod in place.
5B. On FXDWG models, install the fork top plug
and screw it into place to hold the damper rod in
24
place.
6. Push the fork slider and damper rod through the
opening in the bottom of the fork tube.
7. Make sure the oil lock piece is mounted on the
end of the damper rod. Install the fork tube into the
slider (Figure 25) until it bottoms.
8. Install a new washer onto the damper rod Allen
bolt.
9. Apply a non-permanent threadlocking com-
pound to the damper rod Allen bolt threads prior to
414
CHAPTER TEN
installation. Insert the Allen bolt
(Figure
11)
through the lower end of the slider and thread it into
26
the damper rod. Tighten the bolt securely.
NOTE
To protect the oil and dust seal lips,
place a thin plastic bag on top of the
fork tube. Before installing the seals
in the following steps, lightly coat the
bag and the seal lips with fork oil.
10. Slide the fork slider bushing (A, Figure 26), oil
seal spacer (B) and oil seal (C) (with the letters fac-
ing up) down into the fork tube receptacle.
27
NOTE
A 39 mm fork seal driver is required to
install the fork tube bushing and seal
into the fork tube. A number of differ-
ent aftermarket fork seal drivers are
available that can be used for this
purpose. Another method is to use a
piece of pipe or metal collar with cor-
rect dimensions to slide over the fork
tube and seat against the seal. When
selecting or fabricating a driver tool,
it must have sufficient weight to drive
the bushing and oil seal into the fork
tube. A fork seal and cap installer
28
(JIMS part No. 2046) is used in this
procedure.
11. Slide the fork seal driver down the fork tube
and seat it against the seal (Figure 27).
12. Operate the driver and drive the fork slider
bushing and new seal into the fork tube. Continue
until the stopper ring groove in the tube is visible
above the fork seal. Remove the fork seal driver
tool.
13. Install the retaining ring (Figure 28) into the
slider groove. Make sure the retaining ring seats in
17. Fill the fork tube with the correct quantity of
the groove.
Harley-Davidson Type E Fork Oil listed in Table 2.
14A. On all models except FXDWG, install the dust
18. The fork spring is tapered at one end. Install the
seal (Figure 29) and seat it into the slider, then in-
spring (A, Figure 24) with the tapered end facing
stall the dust seal cover.
down toward the damper rod.
14B. On FXDWG models, install the dust cover and
seat it into the slider.
19A. On all models except FXDWG, perform the
following:
15A. On all models except FXDWG, unscrew and
remove the fork top cap.
a. Apply fork oil to the fork top cap O-ring.
15B. On FXDWG models, unscrew and remove the
b. Align the fork top cap with the spring and
fork top plug.
push down on the fork top cap to compress
16. Remove the fork spring.
the spring.
FRONT SUSPENSION AND STEERING
415
21. Install the fork tube as described in this chapter.
29
FRONT FORK
(FXDXT, 2000-ON FXDX)
Front Fork Service
Before assuming that a fork is internally malfunc-
tioning, drain the front fork oil and refill with the
proper type and quantity of fork oil as described in
this chapter. If there is still a problem, such as poor
damping, or a tendency to bottom or top out, follow
the service procedures in this section.
To simplify fork service and to prevent the mix-
30
ing of parts, remove, service and install fork legs in-
dividually.
Removal/Installation
(Fork Not To Be Serviced)
1. Remove the front fender and front wheel (A,
Figure 30) as described in Chapter Eleven.
2. Loosen the upper and lower bracket pinch bolts
(B, Figure 30).
3. If both fork tube assemblies are going to be re-
10
moved, mark them with an R (right side) and L (left
31
side) so the assemblies will be reinstalled on the
correct side.
4. Carefully lower the fork assembly out of the up-
per and lower fork brackets. It may be necessary to
rotate the fork tube slightly while pulling it down
and out. Remove the fork assembly and take it to a
workbench for service. If the fork is not going to be
serviced, wrap it in a bath towel or blanket to protect
the surface from damage.
5. Slowly install the fork tube into the lower fork
bracket then the upper fork bracket.
NOTE
c. Start
the
cap slowly,
making sure it is
not
There is no specification for the loca-
cross-threaded. Tighten it finger-tight.
tion of the top of the fork tube. How-
19B. On FXDWG models, perform the following:
ever, as a guideline, set the fork tube
a. Apply fork oil to the fork top plug O-ring.
approximately 0.08 in (2.0 mm) above
the top surface of the upper fork
b. Align the fork top plug with the spring and
bracket (Figure 31).
push down on the fork top plug to compress
the spring.
6. With the fork assembly in position, tighten the
c. Start the plug slowly, making sure it is not
upper and lower bracket pinch bolts to the torque
cross-threaded. Tighten it finger-tight.
specification listed in Table 2.
20. Place the slider in a vise with soft jaws and
7. Install the front wheel and front fender as de-
tighten the fork top cap, or fork top plug, securely.
scribed in Chapter Nine.
416
CHAPTER TEN
32
33
Removal/Installation
(Fork To Be Serviced)
34
1. Remove the front fender and front wheel as de-
scribed in Chapter Eleven.
2. If both fork tube assemblies are going to be re-
moved, mark them with an R (right side) and L (left
side) so the assemblies will be reinstalled on the
correct side.
3. Place a drain pan under the fork slider.
4. Use an 8 mm Allen wrench and impact driver
and loosen the damper rod cartridge 8 mm Allen
bolt at the base of the slider.
5. Remove the Allen bolt (Figure 32) and drain the
35
fork oil. Pump the slider several times to expel most
of the fork oil. Reinstall the Allen bolt to keep resid-
ual oil in the fork.
6. Carefully pry the cover (A, Figure 33) from the
fork slider.
7. Remove the dust seal and stopper ring (B, Fig-
ure 33) from the fork slider.
8. Lower the fork slider on the fork tube.
NOTE
It may be necessary to slightly heat
the area on the slider around the oil
seal prior to removal. Use a rag
soaked in hot water; do not apply a
36
flame directly to the fork slider.
9. There is an interference fit between the bushing
in the fork slider and the bushing on the fork tube. In
order to remove the fork tube from the slider, pull
hard on the fork tube using quick in-and-out strokes
(Figure 34). Doing so will withdraw the bushing
and the oil seal from the slider.
10. Loosen the upper and lower bracket pinch bolts
(Figure 35).
FRONT SUSPENSION AND STEERING
417
11. Carefully lower the fork assembly out of the
37
FRONT FORK
upper bracket. It may be necessary to rotate the fork
(FXDX 2000-ON, FXDXT)
tube slightly while pulling it down.
12. Lower the fork tube between the upper and the
lower brackets and tighten the lower bracket pinch
bolt.
13. Loosen the fork cap bolt (Figure 36).
14. Loosen the lower bracket pinch bolt and re-
move the fork from the lower bracket.
15. Service the fork assembly as described in this
chapter.
16. Slowly install the fork tube into the lower fork
bracket, then the upper fork bracket.
NOTE
There is no specification to the loca-
tion of the top of the fork tube. How-
ever, as a guideline, set the fork tube
approximately 0.08 in (2.0 mm) above
the top surface of the upper fork
bracket (Figure 31).
17. With the fork assembly in the correct location,
tighten the upper and lower bracket pinch bolts to
the specification in Table 2.
10
18. Install the front wheel and front fender as de-
scribed in Chapter Nine.
Disassembly
Refer to Figure 37.
NOTE
A special fork holding tool is required
to disassemble and assemble this fork
assembly. The fork spring is so strong
that it cannot be compressed suffi-
1.
Rebound
11.
Dust seal
ciently by hand to gain access to the
adjuster
12.
Stopper ring
nut on top of the damper rod. This
2.
Fork cap bolt
13.
Oil seal
special tool is available from motor-
assembly
14.
Oil seal spacer
cycle dealerships or motorcycle parts
3.
O-ring
15.
Slider bushing
suppliers.
4.
Upper spacer
16.
Lower stop
5.
Spring collar
17.
Slider
6.
Lower spacer
18.
Compression
1. Hold the fork in a vertical position and com-
7.
Fork spring
damper adjuster
pletely unscrew the fork cap bolt from the fork tube.
8.
Damper
19.
Nut
The cap bolt cannot be removed at this time as it is
rod/cartridge
20.
Lockwasher
still attached to the damper rod cartridge.
assembly
21.
Washer
9.
Fork tube and
22.
Clamping bolt
2. Turn the fork assembly upside down and drain
bushing
23.
Washer
the residual fork oil into a suitable container. Pump
10.
Dust seal cover
24.
Allen bolt
the fork several times by hand to expel most of the
oil. Dispose of the fork oil properly.
418
CHAPTER TEN
38
39
3. Install the lower end of the fork assembly in the
fork holding tool, following the manufacturer’s in-
40
structions. Make sure the tool is indexed properly in
the lower hole in the slider (Figure 38).
4. Slide the fork tube down into the fork slider to
expose the spring collar.
5. Install the special tool’s upper bolt into the hole
in the spring collar (Figure 39) following the manu-
facturer’s instructions. Make sure the tool is in-
dexed properly in the hole in the spring spacer.
6. Slowly tighten the special tool and compress the
fork assembly until the upper portion of the damper
rod cartridge and nut are exposed (Figure 40).
7. Install an open end wrench on the damper rod
41
cartridge nut (A, Figure 41) and another one on the
flats on the fork cap bolt (B, Figure 41).
8. Hold onto the cap bolt and loosen the damper rod
cartridge nut.
9. Completely unscrew the cap bolt from the
damper rod cartridge.
10. Measure the distance between the top of the
damper rod nut and the top of the damper rod car-
tridge (Figure 42). Note the dimension as it will be
used during assembly.
11. Withdraw the fork cap bolt (A, Figure 43) and
inner rod (B) from the damper rod cartridge.
12. Slowly loosen the special tool and release the
42
spring pressure within the fork assembly.
13. Remove the fork assembly from the special
tool.
14. Remove the upper spacer, spring collar and
lower spacer from above the fork spring.
15. Withdraw the fork spring and damper rod car-
tridge.
16. Slide the slider bushing, spacer, oil seal, retain-
ing ring, dust seal and cover from the fork tube.
Keep them in the order of removal (Figure 44).
FRONT SUSPENSION AND STEERING
419
43
47
NOTE
44
Do not remove the fork tube bushing
unless it is going to be replaced. In-
spect it as described in this chapter.
17. Do not try to remove the lower stop in the base
of the slider. It is pressed into place. If necessary,
have a Harley-Davidson dealership remove it and
install a new one.
18. Inspect the components as described in this
chapter.
10
Inspection
45
Replace any damaged or excessively worn com-
ponents. Repair damaged threads with an appropri-
ately sized metric tap or die. Simply cleaning and
reinstalling unserviceable components will not im-
prove performance of the front suspension.
1. Thoroughly clean all parts in solvent and dry
them. Check the fork tube for signs of wear or
scratches.
2. Check the damper rod cartridge for straightness
and damage (Figure 45).
3. Check the threads and nut (Figure 46) at the top
of the damper rod cartridge for damage.
46
4. Make sure the oil hole (A, Figure 47) in the
damper rod cartridge is clear. Clean out if necessary.
5. Inspect the damper rod cartridge threads for the
Allen bolt (B, Figure 47) for wear or damage.
NOTE
Do not disassemble the fork cap bolt
and rebound adjuster (Figure 48).
Replacement parts are not available.
If this component is defective, replace
the unit as an assembly.
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