Harley Davidson 2005 touring models. Service repair manual — page 6
HOME
f1781x2x
Brake Caliper
Brake Caliper Piston Remover
Piston Remover
(Part No. HD-43293A)
Bridge
CAUTION
Bolt
To prevent air from escaping through the banjo
bolt hole, and to avoid scratching or nicking the
banjo seating surface, use only a tapered, rubber
tipped nozzle on air hose. Loss of air pressure
Low Pressure
will keep the pistons from moving, while any
Tapered,
Air Hose
damage to the banjo seating surface requires
Rubber-Tipped
caliper replacement.
Nozzle
Figure 2-66. Direct Compressed Air Into Banjo Bolt Hole to Force Pistons From Bores
4.
Remove rear wheel. See Section 2.4 REAR WHEEL,
c.
Install bridge bolts and tighten securely.
REMOVAL, steps 2-6.
d.
If the bleeder valve was removed, reinstall finger
5.
Remove caliper from anchor weldment on rear swing-
tight or place a gloved finger over the valve hole.
arm.
e.
Using a tapered, rubber-tipped nozzle on the air
hose (to prevent both loss of air pressure and dam-
age to the banjo seating surface), apply low pres-
CALIPER DISASSEMBLY
sure compressed air into the banjo bolt hole to force
pistons into contact with cushion of tool. See Figure
1.
See Figure 2-63. Remove two pad pins. Remove brake
2-66.
pads from caliper housings.
f.
Remove bridge bolts and separate caliper housings.
2.
Remove three bridge bolts and separate inside and out-
side caliper housings.
3.
Remove anti-rattle spring from channel around boss in
Wooden
f1779x2x
Toothpick
outside caliper housing.
4.
If damaged, cut anchor of rubber damper and remove.
5.
Remove bleeder valve, if damaged.
1WARNING
Pressurized air can blow debris into your face and eyes.
Always wear eye protection or a face shield. Failure to do
so could result in eye injury.
6. Remove four pistons as follows:
Wiper
a. Obtain BRAKE CALIPER PISTON REMOVER (Part
No. HD-43293A). See inset of Figure 2-66.
Square
Seal
b. Seat tool in outside caliper housing aligning holes in
tool with three bridge bolt holes in housing. Place
inside caliper housing over tool aligning bridge bolt
Figure 2-67. Remove Wipers and Square Seals
holes with three holes in tool.
From Piston Bores
2-56
2005 Touring: Chassis
HOME
g. Remove pistons from caliper piston bores. For best
results, wiggle pistons slightly while pulling.
f1782x2x
7. Remove two crossover O-rings from inside caliper hous-
Rubber
ing. Discard O-rings.
Damper
Anchor Bead
CAUTION
Do not use metal objects to remove parts from caliper
Anti-Rattle
piston bores or damage will occur. Damaged pistons or
Spring
Bleeder
bores will leak when reassembled. Use a wooden tooth-
Valve
pick to assist in the removal of parts, if necessary.
8. Using a wooden toothpick, remove wiper and square
seal from each piston bore. Discard wipers and seals.
See Figure 2-67.
CLEANING AND INSPECTION
Figure 2-68. Install Anti-Rattle Spring
1WARNING
CALIPER ASSEMBLY
Use denatured alcohol to clean brake system compo-
nents. Do not use mineral base solvents (such as gaso-
line and paint thinner) or deterioration of rubber parts
1.
Install new square seals into caliper piston bores.
may occur after assembly. Deterioration of components
2.
Install new wipers into caliper piston bores.
may result in premature brake failure, which could result
in death or serious injury.
CAUTION
1. Clean all parts with denatured alcohol or DOT 4 BRAKE
FLUID. Wipe parts dry with a clean, lint free cloth. Blow
Do not use DOT 4 brake fluid for lubrication or in-
out drilled passages and bores with a clean air supply.
creased lever travel will result.
Do not use a wire or similar instrument to clean drilled
passages.
3.
Lubricate the following areas using a thin film of G.E.
VERSILUBE® #G322L SILICONE GREASE (marked
2.
Carefully inspect all components. Replace any parts that
“Piston Lube” in the service parts kit):
appear damaged or worn.
● Inside diameter of square seals and wipers.
a. Check pistons for pitting, scratching or corrosion on
face and also on ground surfaces.
● Caliper piston bores.
b. Inspect caliper piston bore. Replace caliper if bore
● Nose radius and outside diameter of piston.
shows signs of pitting or corrosion. Do not hone
bore for reuse.
NOTE
All other surfaces must be kept clean and dry for assembly.
c. Check rubber damper for cuts, tears or signs of
deterioration.
4.
Carefully insert pistons into bores by hand. If resistance
d. Always replace wipers, square seals and crossover
is felt, remove piston and verify that both seal and wiper
O-rings after caliper disassembly.
are properly installed.
5.
Install new crossover O-rings into two grooves on inside
1WARNING
caliper housing.
Always replace brake pads in pairs. Never replace just
6.
Assemble caliper housings as follows:
one brake pad. Mismatched brake pads can lead to brake
a. Install bleeder valve on outside caliper housing, if
system damage and loss of braking performance, which
removed. Tighten valve to 80-100 in-lbs (9.0-11.3
could result in death or serious injury.
Nm). Install bleeder valve cap.
3.
Inspect brake pads and discs. See INSPECTION at the
b. Place outside caliper housing on workbench with
beginning of this section.
decal side down. Place anti-rattle spring in channel
4. Inspect pad pins for wear and grooving. Replace both
around boss. Spring is not directional. See Figure 2-
pins if wear of either pin exceeds 0.015 inch (0.38 mm).
68.
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c. Mate inside and outside caliper housings and
loosely install two bridge bolts.
1WARNING
d. Tighten bridge bolts to 28-38 ft-lbs (37.9-51.5 Nm).
Use only fresh, uncontaminated DOT 4 brake fluid. Fluid
containers that have been opened may have been con-
e. If rubber damper was removed, lubricate anchor of
taminated by dirt or moisture. Use of contaminated
new damper with isopropyl alcohol or glass cleaner
brake fluid may adversely affect braking ability and lead
and install by pulling rubber bead through hole in
to brake failure which could result in death or serious
outside caliper housing, as shown in Figure 2-68.
injury.
f.
Verify that anti-rattle spring is still seated.
CAUTION
NOTE
Cover adjacent surfaces when removing, draining, filling
All calipers (both front and rear) use the same brake pad set.
and/or bleeding brake system components. Spilling DOT
4 brake fluid on painted or other finished surfaces can
7.
Install new brake pads into caliper with the friction mate-
result in cosmetic damage. Immediately wipe up any
rial facing the brake disc opening. Also, be sure that the
spilled brake fluid and thoroughly clean affected area
pad is oriented so that the curved side faces the rear of
with water or 50/50 mix of water and denatured alcohol.
the vehicle when the caliper is installed. See Figure 2-
64.
3.
Remove two Phillips screws to release cover from rear
brake master cylinder reservoir. Verify that brake fluid
Furthermore, note that the backing plate of each brake
level is 1/8 inch (3.2 mm) below top of reservoir with
pad has either one or two tabs. The pad with two tabs is
master cylinder in a level position. Add DOT 4 BRAKE
installed on the inboard side of the caliper, the pad with
FLUID, if necessary.
the single tab is installed on the outboard side.
8.
Install pad pins and tighten to 180-200 in-lbs (20.3-22.6
1WARNING
Nm).
After installation of caliper and BEFORE moving motor-
NOTE
cycle, pump rear brake pedal until pistons push pads
against the brake disc. If fluid pressure is not pumped
If pad pins do not fit, verify the following: (1) Proper pad set is
up, the rear brake will not be available the first time it is
being used, not two identical pads. (2) Anti-rattle spring is
used, a situation that could result in death or serious
installed as shown in Figure 2-68. (3) Pads are pushed tight
injury.
against anti-rattle spring.
4.
Depress rear brake pedal several times to set brake
pads to proper operating position within caliper. Bleed
brake system. See Section 2.14 BLEEDING HYDRAU-
CALIPER INSTALLATION
LIC BRAKES.
5.
Install master cylinder reservoir cover. Install two Phillips
1.
Install rear wheel. See Section
2.4 REAR WHEEL,
screws to fasten cover to reservoir and tighten to 6-8 in-
INSTALLATION, steps 1-15.
lbs (0.7-0.9 Nm).
6.
Install saddlebags. See Section
2.25 SADDLEBAG,
INSTALLATION.
CAUTION
7.
Test operation of brake lamp with the rear brake applied
To avoid leakage, verify that the washers, banjo bolt,
and the Ignition/Light Key Switch turned to IGNITION.
brake line and caliper bore are completely clean.
2. Connect brake line to caliper using two new steel/rubber
1WARNING
washers and banjo bolt. Tighten bolt to
17-22 ft-lbs
After completing repairs or bleeding the system, always
(23.0-29.8).
test motorcycle brakes at low speed. If brakes are not
operating properly or braking efficiency is poor, testing
1WARNING
at high speeds may result in death or serious injury.
Never mix DOT 4 with other brake fluids (such as DOT 5).
8.
Test ride the motorcycle. If the brakes feel spongy, bleed
Mixing different types of fluid may adversely affect brak-
the system again. See Section
2.14 BLEEDING
ing ability and lead to brake failure which could result in
HYDRAULIC BRAKES.
death or serious injury.
NOTE
To allow new brake pads to “wear in” properly with the brake
disc, avoid making hard stops for the first 100 miles (160 km).
2-58
2005 Touring: Chassis
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BLEEDING HYDRAULIC BRAKES
2.14
GENERAL
Bleed the hydraulic brake system any time a brake line, mas-
ter cylinder or brake caliper has been opened or disassem-
bled, or whenever the brake lever/pedal operation feels
“spongy.” Bleeding evacuates air from the system leaving
only incompressible hydraulic fluid.
NOTE
Harley-Davidson recommends that all brake service be per-
formed by a Harley-Davidson dealer or other qualified techni-
cian.
NOTE
Hydraulic brake fluid bladder-type pressure equipment can
be used to fill brake master cylinders through the bleeder
valve. Remove master cylinder reservoir cover so that sys-
tem cannot pressurize. Do not use pressure bleeding equip-
ment when the hydraulic system is sealed with master
cylinder reservoir cover and gasket in place.
1WARNING
f1994x2x
Never mix DOT 4 with other brake fluids (such as DOT 5).
Mixing different types of fluid may adversely affect brak-
Figure 2-69. Bleeding Hydraulic System
ing ability and lead to brake failure which could result in
death or serious injury.
2.
Remove the two Phillips screws to release cover from
1WARNING
the master cylinder reservoir.
Use only fresh, uncontaminated DOT 4 brake fluid. Fluid
3.
Add DOT 4 BRAKE FLUID to the master cylinder reser-
containers that have been opened may have been con-
voir until the fluid level is 1/8 inch (3.2 mm) from the top.
taminated by dirt or moisture. Use of contaminated
Do not reuse old brake fluid. Use only DOT 4 fluid from a
brake fluid may adversely affect braking ability and lead
sealed container.
to brake failure which could result in death or serious
4.
Depress and hold brake lever/pedal to build up hydraulic
injury.
pressure.
CAUTION
5.
Open bleeder valve about 1/2 turn. Brake fluid will flow
from bleeder valve through tubing. Close bleeder valve
Cover adjacent surfaces when removing, draining, filling
when brake lever/pedal has moved 1/2 to 3/4 of its full
and/or bleeding brake system components. Spilling DOT
range of travel. Allow brake lever/pedal to return slowly
4 brake fluid on painted or other finished surfaces can
to its released position.
result in cosmetic damage. Immediately wipe up any
spilled brake fluid and thoroughly clean affected area
6.
Repeat steps 3-5 until all air bubbles are purged.
with water or 50/50 mix of water and denatured alcohol.
7.
Final tighten the bleeder valve to
80-100 in-lbs
1. Install end of a length of plastic tubing over caliper
(9.0-11.3 Nm). Install the bleeder cap.
bleeder valve. Place free end of tube in a clean con-
tainer. See Figure 2-69. Stand motorcycle upright.
8.
Add brake fluid to the master cylinder reservoir until the
fluid level is about 1/8 inch (3.2 mm) from the top. Do not
reuse brake fluid.
CAUTION
9.
Install the master cylinder reservoir cover. Install two
To prevent dirt and other contaminants from entering the
Phillips screws to fasten the cover to the reservoir.
master cylinder reservoir, thoroughly clean the cover
Tighten the screws to 6-8 in-lbs (0.7-0.9 Nm).
before removal.
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NOTE
Note that the angular shape of the front brake master cylin-
1WARNING
der reservoir cover makes one side thicker than the other.
After completing repairs or bleeding the system, always
Install the cover on the master cylinder reservoir so that the
test motorcycle brakes at low speed. If brakes are not
thicker side is positioned above the brake line fitting.
operating properly or braking efficiency is poor, testing
at high speeds could result in death or serious injury.
10. Test ride motorcycle. Repeat the bleeding procedure if
brakes feel spongy.
2-60
2005 Touring: Chassis
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FRONT FORKS
2.15
CHANGING FORK OIL
Fork
Cap Bolt
See Section
1.2 MAINTENANCE SCHEDULE for the
required service interval, and then proceed as follows:
Table 2-5. Fork Oil Requirements
AMOUNT
FORK
MODEL
TYPE
OZ.
ML
IN.
MM
All models
10.0
295
4.21
107
Fork Stop
except
Cartridge
Left
Road King
See Warning Below
Road King
Conventional
11.1
328
5.24
133
Right
All models
Pinch Bolt
8312
1WARNING
Figure 2-70. Remove Fork Cap Bolt (FLHR/C/S Shown)
Fork oil level in cartridge type forks is carefully mea-
sured from top of tube after pumping damper rod. Any
deviation from instructions can result in incorrect
amount of fork oil. Incorrect amount of fork oil can
adversely affect handling and lead to loss of vehicle
control, which could result in death or serious injury.
NOTE
All touring models with the exception of Road King have the
cartridge type fork on the left side and the conventional type
fork on the right. Road King uses the conventional type fork
on both sides. To change the fork oil on a cartridge type fork,
partial disassembly of the fork is required.
FLHT/C/U, FLTR
1. Remove left fork. See REMOVAL, steps 1-9.
Drain
Plug
2. Partially disassemble left fork. See DISASSEMBLY,
f1786x2x
LEFT FORK, steps 1-13.
Figure 2-71. Remove Fork Oil Drain Plug
3. Position fork assembly upside down over drain pan.
(Right Side Shown)
Allow sufficient time for fork to thoroughly drain (about
10-15 minutes).
FLHR/C/S
4. Assemble left fork. See ASSEMBLY, LEFT FORK, steps
1.
Remove headlamp nacelle. See Section 2.31 WIND-
13-29.
SHIELD/HEADLAMP
NACELLE
(FLHR/C/S),
5. Drain and fill right fork. Removal and disassembly of the
NACELLE REMOVAL
(FLHR/C) or NACELLE
fork is not required. See FLHR/C/S below, steps 3-7.
REMOVAL (FLHRS).
2.
Place suitable blocking under frame to raise front wheel
NOTE
several inches off the floor. Use an hydraulic center
If removing and inverting right fork is the preferred method of
stand on a level surface.
draining, see REMOVAL, steps 4-9.
3.
Remove fork cap bolt from fork tube plug at top of fork
6. Install fork(s) and assemble motorcycle. See INSTALLA-
tube. See Figure 2-70.
TION in this section.
4.
Remove the drain plug from the bottom of the fork slider.
See Figure 2-71.
2005 Touring: Chassis
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5.
When fork oil is fully drained, install drain plug and
tighten to 72-96 in-lbs (8-11 Nm).
Vise Grip
6.
Using a funnel, pour 11.1 ounces (328 ml) of Harley-
Davidson Type E Fork Oil into the fork tube.
Plastic Knob
7.
Install fork cap bolt and tighten to 50-60 ft-lbs (68-81
Nm).
8.
Repeat steps 3-7 on other fork.
9.
Install headlamp nacelle. See Section
2.31 WIND-
SHIELD/HEADLAMP NACELLE (FLHR/C/S), NACELLE
INSTALLATION (FLHR/C) or NACELLE INSTALLATION
(FLHRS).
Rubber Pad
NOTE
If fork is leaking or fails visual inspection, completely disas-
Figure 2-72. Fork Tube Holder (HD-41177)
semble following the instructions under REMOVAL and DIS-
ASSEMBLY. Use the occasion to thoroughly examine all
parts and install a new fork oil seal.
Flat
f1898x2x
Fork Tube
REMOVAL
Plug
1.
Place suitable blocking under frame to raise front wheel
Fork Tube
several inches off the floor. For best results, use an
Holder
Vise
hydraulic center stand on a level surface.
2.
Remove the front wheel and fender. See Section 2.32
FRONT FENDER, REMOVAL.
3.
FLHT/C/U:
a. Remove fairing cap. See Section
2.29 UPPER
FAIRING/WINDSHIELD
(FLHT/C/U), FAIRING
CAP, REMOVAL.
b. Move to front of motorcycle. Loosen two upper outer
Figure 2-73. Install Fork Tube Into Fork Holder
fairing screws. Remove two lower outer fairing
screws.
c. Remove two screws from lower fork bracket to
7.
Holding fork slider to prevent fork from dropping, remove
fork cap bolt from fork tube plug. Slide fork tube down
release auxiliary lamp bracket, chrome skirt and
inner fairing. Remove chrome skirt.
and out of upper fork bracket, fork stop, lower fork
bracket, and slider cover.
FLTR:
8.
Thread fork cap bolt back into fork tube plug to prevent
a. Remove instrument nacelle. See Section
2.30
loss of fork oil while handling.
UPPER FAIRING/WINDSHIELD (FLTR), INSTRU-
MENT NACELLE, REMOVAL.
9.
Move front fork to bench area. Place suitable drain pan
on floor beneath vise.
FLHR/C/S:
10.
Repeat steps 4-9 to remove right fork.
a. Remove headlamp nacelle. See Section
2.31
WINDSHIELD/HEADLAMP NACELLE (FLHR/C/S),
NACELLE REMOVAL
(FLHR/C) or NACELLE
REMOVAL (FLHRS).
DISASSEMBLY
4.
Standing at front of vehicle, loosen pinch bolt (with lock-
washer) on left side of lower fork bracket, but do not
LEFT FORK
remove. See Figure 2-70.
Cartridge Type - All Models Except Road King
5.
Loosen fork cap bolt from fork tube plug at top of fork
tube, but do not remove.
NOTE
6.
Spray glass cleaner on fork tube above the rubber fork
Since Road King uses the conventional type fork on both
stop. After lubricating surfaces, move fork stop up fork
sides, see DISASSEMBLY, RIGHT FORK, for Road King
tube until it contacts bottom of upper fork bracket.
instructions.
2-62
2005 Touring: Chassis
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a. Clamp end of tool in vise in a horizontal position
with plastic knobs facing toward you.
Length
Retaining Pins (3)
b. With the fork cap bolt topside, clamp fork tube
Adjuster
between rubber pads on inboard side of tool.
Screw
Tighten knobs until fork tube is securely held.
3.
Remove fork cap bolt from fork tube plug. Remove and
discard quad ring seal.
4.
Using flat, unthread fork tube plug from fork tube. See
Figure 2-73.
Spring
Compressor
5.
Pull up on fork slider to compress fork assembly, which
causes the damper rod to protrude from the top of the
fork tube.
6.
Holding locknut, remove fork tube plug from threaded
end of damper rod. Remove O-ring from fork tube plug.
Discard O-ring.
7.
Remove fork assembly from fork tube holder. Turning
fork upside down, drain fork oil into drain pan.
Damper Rod
8.
Remove fork tube holder from vise.
Extension Tool
Post
9.
Obtain the FORK SPRING COMPRESSING TOOL (HD-
45966) shown in Figure 2-74. Install as follows:
a. Clamp tool in vise in a vertical position with length
f2188x2x
adjuster screw topside.
b. Pull up on fork slider to compress fork assembly.
Figure 2-74. Fork Spring Compressing Tool (HD-45966)
c. Place hole at bottom of fork slider over post at bot-
tom end of tool.
Locknut
d. With the smaller OD topside, place spring compres-
sor over locknut, spring seat and flat washer of fork
assembly.
CAUTION
Use only hand tools to turn length adjuster screw on fork
spring compressing tool. Do not use an air impact
wrench or tool damage can occur.
e. Adjust tool as necessary until three retaining pins
engage blind holes in spring compressor. Turn
length adjuster screw in a counterclockwise direc-
tion to lengthen, a clockwise direction to shorten.
f2189x2x
1WARNING
Figure 2-75. Compress Fork Spring
Retaining pins must fully engage blind holes or spring
compressor may rotate out of position during compres-
sion of spring. If spring compressor rotates out of posi-
1. Remove the fork assembly. See REMOVAL in this sec-
tion, sudden extension of spring can cause parts to fly
tion.
out, possibly resulting in minor or moderate injury.
f.
Turn retaining pins as necessary to lock position of
CAUTION
spring compressor.
Exercise caution to avoid scratching or nicking fork
g. Turn length adjuster screw in a clockwise direction
tube. Damaging tube can result in fork oil leaks after
to compress spring.
assembly.
10. Using deepwell socket to avoid unnecessary spring
2. Obtain the FORK TUBE HOLDER (HD-41177). See Fig-
compression, remove locknut from end of damper rod.
ure 2-72. Proceed as follows:
See Figure 2-75.
2005 Touring: Chassis
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11. Turn length adjuster screw in a counterclockwise direc-
15. Place a shop rag on the floor, and turning fork assembly
tion to release tension on fork spring. Loosen retaining
upside down, press end of spring against rag. While
pins and remove spring compressor. Remove spring
compressing spring to prevent rotation of damper car-
seat and flat washer.
tridge, remove 6mm screw from end of fork slider. Use
an air impact wrench for best results. Discard
6mm
12. Remove fork assembly from tool and remove tool from
screw and copper crush washer.
vise. Remove fork spring from fork tube.
16. Remove spring and damper cartridge from fork tube.
13. Obtain damper rod extension tool shown in Figure 2-76.
Thread extension tool onto end of damper rod. Turn fork
CAUTION
assembly upside down over drain pan and slowly pump
damper rod at least twenty times until rod moves freely.
Do not expand or stretch retaining clip to remove from
See Figure 2-77.
fork tube or clip may become bent or distorted.
NOTE
17. Using pick tool, remove retaining clip between fork slider
and fork tube.
If just changing the fork oil, continue procedure at ASSEM-
18. Remove fork tube from fork slider.
BLY, LEFT FORK, step 13. If overhauling the fork assembly,
continue with step below.
NOTE
To overcome any resistance, use the fork tube as a slide
14. Remove extension tool from damper rod. Install fork
hammer, that is, first push fork tube into fork slider and then
spring back into fork tube.
pull it outward with a moderate amount of force. Repeat this
sequence until fork tube separates from fork slider.
19. Slide fork oil seal, slider spacer and slider bushing off
end of fork tube. Discard fork oil seal and slider bushing.
f2186x2x
M10 X 1.0
20. Gently pry at split line to expand fork leg bushing, and
Thread Size
then remove from groove at end of fork tube. Discard
fork leg bushing.
21. Remove lower stop from fork slider, or end of damper
cartridge if still installed.
RIGHT FORK
Figure 2-76. Damper Rod Extension Tool
Conventional Type - All Models
1.
Remove the fork assembly. See REMOVAL in this sec-
tion.
f2187x2x
2.
Remove nuts, lockwashers, flat washers and axle holder
from studs at end of fork slider.
CAUTION
Exercise caution to avoid scratching or nicking fork
tube. Damaging tube can result in fork oil leaks after
assembly.
3.
Obtain the FORK TUBE HOLDER (HD-41177). See Fig-
ure 2-72. Proceed as follows:
a. Clamp end of tool in vise in a horizontal position
with plastic knobs facing toward you.
b. With the fork cap bolt topside, clamp fork tube
between rubber pads on inboard side of tool.
Tighten knobs until fork tube is securely held. See
Figure 2-73.
4.
Remove fork cap bolt from fork tube plug. Remove and
Figure 2-77. Pump Damper Rod Extension Tool
discard O-ring.
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2005 Touring: Chassis
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5. Using flat, slowly unthread fork tube plug from fork tube.
Be aware that fork tube plug is under spring pressure, so
f2045x2x
have a firm grasp on plug as the last thread is turned.
Remove and discard O-ring from fork tube plug.
6. Remove fork spring from fork tube.
7. Remove fork assembly from fork tube holder.
8. Turning fork upside down, drain fork oil into drain pan.
For best results, slowly pump fork tube and slider at least
ten times.
9. Install fork spring back into fork tube.
10. Place a shop rag on the floor, and turning fork assembly
upside down, press end of spring against rag. While
compressing spring to prevent rotation of damper tube,
Figure 2-78. Measure Fork Tube Runout
remove 6mm screw from end of fork slider. Use an air
impact wrench for best results. Discard 6mm screw and
copper crush washer.
5.
Check the fork tube and slider for scoring, scratches and
11. Remove fork spring and damper tube from fork tube.
excessive or abnormal wear. Replace parts as neces-
sary. Set the fork tube on V-blocks and measure the
12. Remove wear ring and rebound spring from damper
runout using a dial indicator gauge. Replace fork if
tube.
runout exceeds 0.008 inch (0.2 mm). See Figure 2-78.
CAUTION
6.
Inspect upper fork springs for damage or distortion. Ver-
ify that free length is a minimum of 15 inches (381.0 mm)
Do not expand or stretch retaining clip to remove from
on cartridge type forks, 18.5 inches (469.9 mm) on the
fork tube or clip may become bent or distorted.
conventional type. Replace rebound spring on the con-
ventional type fork if the free length is less than 15/16
13. Using pick tool, remove retaining clip between fork slider
inch
(23.8 mm) or whenever the upper fork spring
and fork tube.
requires replacement.
14. Remove fork tube from fork slider.
NOTE
To overcome any resistance, use the fork tube as a slide
ASSEMBLY
hammer, that is, first push fork tube into fork slider and then
pull it outward with a moderate amount of force. Repeat this
sequence until fork tube separates from fork slider.
LEFT FORK
15. Slide fork oil seal, slider spacer and slider bushing off
end of fork tube. Discard fork oil seal and slider bushing.
Cartridge Type - All Models Except Road King
16. Gently pry at split line to expand fork leg bushing, and
then remove from groove at end of fork tube. Discard
NOTE
fork leg bushing.
Since Road King uses the conventional type fork on both
17. Remove the lower stop from the fork slider.
sides, see ASSEMBLY, RIGHT FORK, for Road King instruc-
tions.
CLEANING AND INSPECTION
CAUTION
Exercise caution to avoid scratching or nicking fork
1. Thoroughly clean and inspect all parts. Replace any
tube. Damaging tubes can result in fork oil leaks after
parts that are bent, broken or obviously damaged.
assembly.
2. Inspect fork cap bolt quad ring seal and fork tube plug O-
ring for cuts, tears or signs of deterioration. Replace if
1.
Coat fork leg bushing ID with clean fork oil. Expand fork
necessary.
leg bushing at split line only so far as required to slip
over end and into groove of fork tube.
3. Replace the retaining clip if bent or distorted.
2.
Slide damper cartridge into fork tube, so that cartridge
4. Check the slider and fork leg bushings for scratches or
excessive wear. Always replace bushings in a set if
end drops through hole at bottom of fork tube. Install
lower stop at end of damper cartridge.
either bearing is damaged or worn.
2005 Touring: Chassis
2-65
HOME
3.
Install fork slider in fork tube holder. Slide fork tube into
fork slider.
f2190x2x
4.
Coat slider bushing ID with clean fork oil. Slide slider
bushing down fork tube.
5.
Slide slider spacer down fork tube until it contacts slider
bushing.
6.
Obtain the FORK OIL SEAL INSTALLER (HD-34634).
See Figure 2-79. Proceed as follows:
a. Slide the fork oil seal installer down the fork tube,
and using the tool like a slide hammer, drive slider
bushing into counterbore of fork slider. Remove tool.
NOTE
Place masking tape over edge of fork tube to avoid damaging
lip of fork oil seal during installation.
b. Coat new fork oil seal ID with clean fork oil. With the
Figure 2-81. Pump Damper Rod Extension Tool
lip garter spring side facing down (toward the fork
slider), slide seal down fork tube until it contacts
slider spacer. Remove masking tape from edge of
d. Using the tool like a slide hammer, drive fork oil seal
fork tube.
down fork tube until retaining clip groove is visible in
fork slider ID. See Figure 2-80. Remove tool.
c. Slide the fork oil seal installer down the fork tube
until it contacts the fork oil seal.
CAUTION
Do not expand or stretch retaining clip to install on fork
tube or clip may become bent or distorted.
f1901x2x
e. Slide the retaining clip down the fork tube until it
contacts the fork oil seal. Install retaining clip in the
fork slider groove.
7.
Install fork spring into fork tube.
8.
Remove fork assembly from fork tube holder.
9.
Place a shop rag on the floor, and turning fork assembly
upside down, press end of spring against rag.
Figure 2-79. Fork Oil Seal Installer (HD-34634)
10. Install new 6mm screw with copper crush washer. Slide
screw through hole at bottom of fork slider and start into
end of damper cartridge.
f1902x2x
11. While compressing spring to prevent rotation of damper
cartridge, tighten 6mm screw to 132-216 in-lbs (14.9-
24.4 Nm).
12. Remove fork spring from fork tube.
13. With the fork tube topside, clamp fork slider (not the fork
tube) into fork tube holder.
NOTE
Install the drain plug at the bottom of the fork slider, if
removed. Tighten the plug to 72-96 in-lbs (8-11 Nm).
14. Fill the fork tube as follows:
a. Obtain damper rod extension tool shown in Figure
2-76. Thread extension tool onto end of damper rod.
b. Pour 5 ounces (147.9 ml) of Harley-Davidson Type
Figure 2-80. Install Fork Oil Seal
E Fork Oil into the fork tube.
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2005 Touring: Chassis
HOME
c. Grasping extension tool, slowy pump the damper
e. Pull out plunger to suck fork oil from fork tube.
rod until resistance is felt, and then pump five more
Observe fork oil through transparent tube as it is
times. See Figure 2-81.
drawn into cylinder. If no oil is drawn through trans-
parent tube, add enough oil so that tool usage sets
d. Place the damper rod in the fully bottomed position.
fork oil level.
e. Remove extension tool from end of damper rod.
f.
Remove rod from fork tube. Push plunger into cylin-
der to eject excess fork oil into suitable container.
f.
Pour 6 more ounces (177.5 ml) of fork oil into the
fork tube.
g. If necessary, repeat steps 15(d) thru 15(f). Level is
correct when no fork oil is observed being drawn
15.
Adjust the fork oil level, so that it is 4.21 inches (107
through transparent tube.
mm) from the top of the fork tube with the fork com-
pressed. Proceed as follows:
1WARNING
a. Obtain the FRONT FORK OIL LEVEL GAUGE (HD-
Be sure fork oil level is correct. The incorrect amount of
59000B). See Figure 2-82.
fork oil can adversely affect handling and may lead to
b. Loosen thumbscrew on metal ring and move it up or
loss of vehicle control, which could result in death or
down the rod until the bottom of the ring is 4.21
serious injury.
inches (107 mm) from the end of the rod. Tighten
16. With the closer spaced coils at the bottom, slide fork
thumbscrew.
spring into fork tube.
c. Push the plunger on the cylinder all the way in.
17. Pull up on fork slider to compress fork assembly, which
causes the damper rod and spring to protrude from the
d. Insert rod into top of fork tube until metal ring rests
flat on top of fork tube. See Figure 2-83.
top of the fork tube.
18. Thread damper rod extension tool onto end of damper
rod.
19. Remove fork assembly from fork tube holder. Remove
fork tube holder from vise.
20. Obtain the FORK SPRING COMPRESSING TOOL (HD-
45966) shown in Figure 2-74. Install as follows:
a. Clamp tool in vise in a vertical position with length
adjuster screw topside.
b. Pull up on fork slider to compress fork assembly.
c. Place hole at bottom of fork slider over post at bot-
tom end of tool.
d. Place flat washer rounded side up over damper rod
extension tool and on top of spring. Place spring
Figure 2-82. Front Fork Oil Level Gauge (HD-59000B)
seat concave side up on top of flat washer. With the
smaller OD topside, place spring compressor over
spring seat and flat washer.
f2168x2x
CAUTION
Use only hand tools to turn length adjuster screw on fork
spring compressing tool. Do not use an air impact
wrench or tool damage can occur.
e. Adjust tool as necessary until three retaining pins
engage blind holes in spring compressor. Turn
length adjuster screw in a counterclockwise direc-
tion to lengthen, a clockwise direction to shorten.
1WARNING
Retaining pins must fully engage blind holes or spring
compressor may rotate out of position during compres-
sion of spring. If spring compressor rotates out of posi-
tion, sudden extension of spring can cause parts to fly
Figure 2-83. Remove Excess Fork Oil
out, possibly resulting in minor or moderate injury.
2005 Touring: Chassis
2-67
HOME
f.
Turn retaining pins as necessary to lock position of
f1974x2x
spring compressor. See Figure 2-75.
g. Turn length adjuster screw in a clockwise direction
to compress spring. See Figure 2-75.
21.
After a number of turns, pull up on extension tool to raise
1
damper rod. If threaded portion of rod cannot be pulled
2
completely out of spring, compress spring further.
10
22.
Repeat step 21 until threaded portion of rod can be
3
pulled completely out of spring. Remove extension tool,
4
but do not let go of damper rod.
23.
Thread locknut onto damper rod until it contacts shoul-
5
6
der. Use a deepwell socket for best results.
24.
Install new O-ring onto fork tube plug. Thread fork tube
plug onto threaded end of rod until it bottoms. Now turn
7
locknut in a counterclockwise direction until it makes firm
contact with the fork tube plug. Tighten locknut to 13-20
11
ft-lbs (18-27 Nm).
12
25.
Turn length adjuster screw in a counterclockwise direc-
8
tion to release tension on fork spring. Loosen retaining
pins and remove spring compressor. Remove fork
13
assembly from tool and remove tool from vise.
26.
Install fork tube holder in vise. Clamp fork tube into fork
14
15
tube holder.
16
27.
Tighten fork tube plug to 22-58 ft-lbs (30-79 Nm).
28.
Install new O-ring onto fork cap bolt. Thread fork cap
bolt into fork tube plug to prevent loss of fork oil while
handling.
29.
Remove fork assembly from fork tube holder.
17
9
RIGHT FORK
18
Conventional Type - All Models
CAUTION
19
20
Exercise caution to avoid scratching or nicking fork
tube. Damaging tubes can result in fork oil leaks after
assembly.
21
1.
Coat fork leg bushing ID with clean fork oil. Expand fork
leg bushing at split line only so far as required to slip
1.
Fork cap bolt
12. Lip seal
over end and into groove of fork tube.
2.
Quad ring seal
13. Slider spacer
2.
Install new wear ring in groove at top of damper tube.
3.
Fork tube plug
14. Slider bushing
Install rebound spring on opposite end.
4.
O-Ring
15. Fork leg bushing
5.
Locknut
16. Lower stop
3.
With the wear ring topside, slide damper tube into fork
6.
Spring seat
17. Fork slider
tube, so that tube end drops through hole at bottom of
7.
Flat washer
18. Plug
fork tube. Install lower stop at end of damper tube.
8.
Spring
19. Flat Washer
4.
Install fork slider in fork tube holder. Slide fork tube into
9.
Damper cartridge
20. Copper washer
fork slider.
10.
Fork tube
21. Screw (6mm)
5.
Coat slider bushing ID with clean fork oil. Slide slider
11.
Retaining clip
bushing down fork tube.
6.
Slide slider spacer down fork tube until it contacts slider
Figure 2-84. Left Side Fork - Cartridge Type
bushing.
(All Models Except Road King)
2-68
2005 Touring: Chassis
HOME
7. Obtain the FORK OIL SEAL INSTALLER (HD-34634).
See Figure 2-79. Proceed as follows:
1
f1975x2x
2
a. Slide the fork oil seal installer down the fork tube,
and using the tool like a slide hammer, drive slider
bushing into counterbore of fork slider. Remove tool.
3
4
NOTE
Place masking tape over edge of fork tube to avoid damaging
lip of fork oil seal during installation.
b. Coat new fork oil seal ID with clean fork oil. With the
lip garter spring side facing down (toward the fork
5
slider), slide seal down fork tube until it contacts
slider spacer. Remove masking tape from edge of
fork tube.
10
c. Slide the fork oil seal installer down the fork tube
until it contacts the fork oil seal.
11
6
d. Using the tool like a slide hammer, drive fork oil seal
12
down fork tube until retaining clip groove is visible in
fork slider ID. See Figure 2-80. Remove tool.
13
7
14
CAUTION
Do not expand or stretch retaining clip to install on fork
8
15
tube or clip may become bent or distorted.
e. Slide the retaining clip down the fork tube until it
contacts the fork oil seal. Install retaining clip in the
fork slider groove.
16
8. Install fork spring into fork tube.
17
9. Remove fork assembly from fork tube holder.
10. Place a shop rag on the floor, and turning fork assembly
9
upside down, press end of spring against rag.
11. Install new 6mm screw with copper crush washer. Slide
18
21
screw through hole at bottom of fork slider and start into
end of damper tube.
19
22
12. While compressing spring to prevent rotation of damper
tube, tighten 6mm screw to 132-216 in-lbs (14.9-24.4
23
Nm).
20
24
13. Remove fork spring from fork tube.
14. With the fork tube topside, clamp fork slider (not the fork
1.
Fork cap bolt
13.
Slider bushing
tube) into fork tube holder.
2.
Quad ring seal
14.
Fork leg bushing
3.
Fork tube plug
15.
Lower stop
NOTE
4.
O-Ring
16.
Fork slider
Install the drain plug at the bottom of the fork slider, if
5.
Spring
17.
Plug
removed. Tighten the plug to 72-96 in-lbs (8-11 Nm).
6.
Wear ring
18.
Flat Washer
7.
Damper tube
19.
Copper washer
15. Pour 11.1 ounces (328 ml) of Harley-Davidson Type E
8.
Rebound spring
20.
Screw (6mm)
Fork Oil into the fork tube.
9.
Fork tube
21.
Axle holder
16. Adjust the fork oil level, so that it is 5.24 inches (133
10. Retaining clip
22.
Flat washer (2)
11. Lip seal
23.
Lockwasher (2)
mm) from the top of the fork tube with the fork com-
pressed. Proceed as follows:
12. Slider spacer
24.
Nut (2)
a. Obtain the FRONT FORK OIL LEVEL GAUGE (HD-
Figure 2-85. Right Side Fork - Conventional Type
59000B). See Figure 2-82.
(All Models)
2005 Touring: Chassis
2-69
HOME
b. Loosen thumbscrew on metal ring and move it up or
INSTALLATION
down the rod until the bottom of the ring is 5.24
inches (133 mm) from the end of the rod. Tighten
1.
Remove fork cap bolt.
thumbscrew.
2.
Standing at front of vehicle, slide fork tube up and into
c. Push the plunger on the cylinder all the way in.
slider cover, lower fork bracket, fork stop, and upper fork
bracket. Install fork cap bolt.
d. Insert rod into top of fork tube until metal ring rests
3.
Move rubber fork stop down fork tube until it contacts top
flat on top of fork tube. See Figure 2-83.
of lower fork bracket. Lubricate surfaces with glass
e. Pull out plunger to suck fork oil from fork tube.
cleaner, if necessary.
Observe fork oil through transparent tube as it is
4.
Install pinch bolt (with lockwasher) on left side of lower
drawn into cylinder. If no oil is drawn through trans-
fork bracket. See Figure 2-70. Tighten pinch bolt to 30-
parent tube, add enough oil so that tool usage sets
35 ft-lbs (41-48 Nm).
fork oil level.
5.
Tighten fork cap bolt to 50-60 ft-lbs (68-81 Nm).
f.
Remove rod from fork tube. Push plunger into cylin-
6.
Repeat steps 1-5 on other fork, if removed.
der to eject excess fork oil into suitable container.
7.
Install the front fender and wheel. See Section 2.32
g. If necessary, repeat steps 16(d) thru 16(f). Level is
FRONT FENDER, INSTALLATION.
correct when no fork oil is observed being drawn
8.
FLHT/C/U:
through transparent tube.
a. Slide chrome skirt into position between auxiliary
lamp bracket and inner fairing. To avoid possible
1WARNING
wire damage, be sure that trim strip is installed on
top edge of skirt. Install two screws to secure auxil-
Be sure fork oil level is correct. The incorrect amount of
iary lamp bracket, chrome skirt and inner fairing to
fork oil can adversely affect handling and may lead to
lower fork bracket.
loss of vehicle control, which could result in death or
b. Move to front of motorcycle. Install two lower outer
serious injury.
fairing screws. Tighten two upper outer fairing
screws.
17. With the closer spaced coils at the bottom, slide fork
spring into fork tube.
c. Install fairing cap. See Section 2.29 UPPER FAIR-
ING/WINDSHIELD
(FLHT/C/U), FAIRING CAP,
18. Install new O-ring onto fork tube plug. Compressing fork
INSTALLATION
spring with end of fork tube plug, thread fork tube plug
FLTR:
into fork tube. Tighten fork tube plug to 22-58 ft-lbs (30-
79 Nm).
a. Install instrument nacelle. See Section 2.30 UPPER
FAIRING/WINDSHIELD
(FLTR), INSTRUMENT
19. Install new quad ring seal onto fork cap bolt. Thread fork
NACELLE, INSTALLATION.
cap bolt into fork tube plug to prevent loss of fork oil
FLHR/C/S:
while handling.
a. Install headlamp nacelle. See Section 2.31 WIND-
20. Loosely install axle holder, flat washers, lockwashers
SHIELD/HEADLAMP NACELLE
(FLHR/C/S),
and nuts on studs at end of fork slider.
NACELLE INSTALLATION (FLHR/C) or NACELLE
INSTALLATION (FLHRS).
2-70
2005 Touring: Chassis
HOME
LOWER FORK BRACKET COVER/AIR DAM
2.16
LOWER FORK BRACKET COVER
(FLHRS)
REMOVAL
1. Moving to the back of the lower fork bracket, remove two
hex screws (with flat washers) to release cover flange.
2. Holding cover to prevent from dropping, remove T40
TORX screw at bottom.
7590
INSTALLATION
Figure 2-86. Air Dam
1. With the concave side up, align holes in cover flange
with holes at back of the lower fork bracket.
NOTE
AIR DAM (FLTR)
Plastic plug(s) at back of lower fork bracket will prevent
proper cover installation. Remove and discard plug(s), if
REMOVAL
present.
NOTE
3.
Start two hex screws (with flat washers) to fasten cover
By allowing the flow of air to pass under the fuel tank and
flange to bracket.
over the cylinder heads, removing the air dam evacuates
4.
Start T40 TORX screw at bottom of cover engaging off-
heated air and provides some relief to the rider in warmer
set hole in front brake line bracket.
temperatures (70˚ F. or above).
5.
Alternately tighten two hex screws to 70-110 in-lbs (7.9-
1.
Moving to the back of the lower fork bracket, remove two
12.4 Nm).
screws (with flat washers) to release air dam. See Fig-
ure 2-86.
6.
Tighten T40 TORX screw to 120-180 in-lbs (13.6-20.3
Nm).
2.
To keep out dirt and debris, reinstall two screws (with flat
washers) into holes of lower fork bracket. Tighten screws
7.
Verify that cover does not contact brake lines to front
to 120-144 in-lbs (13.6-16.3 Nm).
brake calipers or master cylinder reservoir. Adjust either
brake line bracket or cover if necessary.
INSTALLATION
NOTE
Reinstall air dam in colder weather.
1.
With the concave side down, align holes in air dam with
holes at back of the lower fork bracket.
NOTE
Plastic plug(s) at back of lower fork bracket will prevent
proper cover installation. Remove and discard plug(s), if
present.
2.
Install two screws (with flat washers) to fasten air dam to
fork bracket. Tighten screws to 120-144 in-lbs (13.6-
16.3 Nm).
2005 Touring: Chassis
2-71
HOME
STEERING HEAD BEARINGS
2.17
LUBRICATION
At the 1000 mile (1600 km) service interval, and at every
Steering
10,000 mile (16,000 km) service interval thereafter, grease
Head
the steering head bearings using Special Purpose Grease,
Part No. 99857-97. Turn handlebar full right to access the
grease fitting at the left side of the steering head. Connect
grease gun to fitting and inject grease until it exudes from top
and bottom of steering head. See Figure 2-87.
At every 25,000 mile (40,000 km) service interval, check the
swing-by following the CHECKING procedure below.
At every 50,000 mile (80,000 km) service interval, disassem-
Grease
ble the steering head and inspect the bearings for brinelling,
Fitting
scoring, or other damage. Replace and/or repack the bear-
ings as required.
f2108x2x
CHECKING
Figure 2-87. Steering Head Bearing Grease Fitting
1.
Using an hydraulic center stand on a level surface, raise
the vehicle so that the front and rear tires are the same
ADJUSTMENT
distance from the floor.
2.
Verify that motorcycle is in stock configuration. Remove
1.
On FLHT/C/U models, remove outer fairing and radio
all non-factory accessories, since they can influence
(storage box on FLHT). On FLHR/C/S, remove head-
front end swing momentum (and lead to improper adjust-
lamp nacelle. On FLTR models, remove the instrument
ment).
bezel.
3.
Turn the front wheel until contact is made with the left
2.
Loosen the pinch bolts on the lower fork bracket and
fork stop and then let go. The wheel should swing right,
slide the rubber fork stops up slightly on the fork tubes.
left, then right and stop. The wheel need not stop near
This will prevent any binding of the front end when the
the center or straight-forward position, but it must move
adjustment is made. See Figure 2-70.
to the right making a partial third swing. See frame C of
3.
Bend tab on lock plate away from flat of fork stem nut.
Figure 2-88.
Loosen the fork stem nut. See Figure 2-89.
4.
To correct a swing pattern that is too short or too long,
4.
Fashion a bearing adjuster tool using a drill rod
16
see ADJUSTMENT below.
inches long. See lower frame of Figure 2-90.
A
B
C
D
Steering head is set up too
Steering head is still set up too
Steering head adjustment is
Steering head is set up too
tight. The wheel stops in its first
tight. The wheel stops in its
OK. The wheel need not stop
loose. The wheel begins its
swing.
second swing. A steering head
near the center, but it must
fourth swing. A steering head
that is too tight can interfere
move to the right making a
that is too loose can interfere
with the vehicle’s ability to
partial third swing.
with the vehicle’s ability to
absorb a weave.
absorb a wobble.
CORRECT
f1475x2x
Figure 2-88. Check Steering Head Bearing Swing-By
2-72
2005 Touring: Chassis
HOME
f1907x2x
Fork Stem
9441
Nut
Upper Fork Bracket
Bearing
Adjuster
Star Nut
Lock
Plate
Figure 2-89. Fork Stem Nut
f1792x2x
5/32 Inch goes back
for 1-1/4 Inches.
To decrease the number of swings, stand on the left side
5/32 Inch
A
of the vehicle and insert the rod to engage the notches
1/8 Inch
of the bearing adjuster (star) nut under the fork bracket.
NOTE
2 Inches
Each Rod is 1/4 Inch Diameter
Start of
Push forward to rotate the nut clockwise.
by 16 Inches Long.
Bend
A
End View
NOTE
Turning the bearing adjuster nut as little as one notch will
A
make a noticeable difference in the swing pattern.
To increase the number of swings, stand on the right
side of the vehicle and insert the rod to engage the
notches of the bearing adjuster nut. Push forward to
rotate the nut counterclockwise.
5. Tighten the fork stem nut to 60-80 ft-lbs (81-109 Nm).
The tightness of the nut will affect the swing pattern.
6. Recheck the swing pattern. See step 3 under CHECK-
ING. Repeat steps 4-6 above until swing pattern is cor-
rect.
7. Tighten pinch bolts to 30-35 ft-lbs (41-48 Nm) and prop-
erly position the rubber fork stops.
FLTR
8. Verify that the fork stem nut is tightened to 60-80 ft-lbs
All Others
Road Glide
(81-109 Nm). Bend tab on lockplate against flat of fork
stem nut.
9. On FLHT/C/U models, install radio
(storage box on
FLHT) and outer fairing. On FLHR/C/S, install headlamp
nacelle. On FLTR models, install the instrument bezel.
Figure 2-90. Fashion Steering Head Bearing
10. Recheck the swing pattern. See step 3 under CHECK-
Adjustment Tool From Drill Rod
ING. Repeat ADJUSTMENT procedure if swing pattern
is not correct.
2.
Remove the front wheel and fork assemblies. Remove
brake line from lower fork bracket.
REMOVAL
3.
Bend tab away from flat of fork stem nut. Remove nut.
1. On FLHT/C/U models, remove the auxiliary lamp
bracket, outer fairing and radio (storage box on FLHT).
4.
Remove the bearing adjuster and fork stem assembly.
On FLHR/ C, remove headlamp nacelle. On FLTR mod-
See upper frame of Figure 2-90. Remove dust shield
els, remove the instrument nacelle.
and bearing from top of steering head.
2005 Touring: Chassis
2-73
HOME
Steering Head Bearing Race Remover
1. Install Remover on Upper Race
(Part No. HD-39301A)
Remover
Collet
Universal Driver
(Part No. HD-33416)
2. Install Collet on Driver
Figure 2-91. Steering Head Bearing Race Removal Tools
INSPECTION
1.
Check the bearing races in the steering head. If pitted or
grooved, replace both the bearings and races.
2.
Turn bearings in races. Replace the bearings if they do
not move freely and smoothly. Always replace both races
and bearings even if one race and bearing appears
good.
STEERING HEAD BEARING RACE REMOVAL
3. Install Driver in Remover
and Remove Upper Race
NOTE
To remove the upper and lower steering head bearing races,
use the Steering Head Bearing Race Remover (Part No. HD-
39301A) with the Universal Driver (Part No. HD-33416). See
Figure 2-91.
Proceed as follows:
1. With the tapered side down, seat the two-piece remover
tool on the upper bearing race leaving a gap in the mid-
dle. See Figure 2-92.
2. Install the collet on the driver.
3. Insert the driver at the bottom of the steering head tube,
and while holding the remover tool on the race, center
the collet in the gap. Tap the driver to remove the upper
race.
4. Reverse the tool and repeat the procedure to remove the
f1279x2x
4. Remove Lower Race
lower bearing race.
Figure 2-92. Remove Upper and Lower
REMOVING BEARING FROM FORK STEM
Steering Head Bearing Races
1.
Chisel cage retaining rollers off bearing on fork stem.
2.
Turn the stem upside down while heating the inner race.
Race will expand and fall free.
2-74
2005 Touring: Chassis
HOME
ASSEMBLY
1
WARNING
1. Pack new bearings with Harley-Davidson SPECIAL
Be sure fork stem nut adjustment is correct. An improp-
PURPOSE GREASE, Part No. 99857-97.
erly adjusted nut can adversely affect handling and may
lead to loss of vehicle control, which could result in
2. Install dust shield on fork stem. Use a sleeve that will
death or serious injury.
contact only the inner race of the new bearing, then
press the bearing into place on fork stem.
2.
Install upper fork bracket and fork stem nut. Tighten nut
to
60-80 ft-lbs
(81-109 Nm). Bend the lockplate tab
3. Install new bearing races in steering head using STEER-
against the nut flat. See Figure 2-89.
ING HEAD BEARING RACE INSTALLATION TOOL,
Part No. HD-39302.
3.
Install fork assemblies, radio (storage box on FLHT),
outer fairing and auxiliary lamp bracket. On FLHR/C/S,
install headlamp nacelle. On FLTR models, install the
instrument bezel.
INSTALLATION
4.
Install the front wheel and bleed the front brake. Check
swing-by under CHECKING in this section.
1. Install the fork stem assembly into the steering head.
Install the bearings and dust shield. Install the bearing
adjuster nut. Snug the adjuster nut down until bearing
play is taken up and the fork stem turns freely. Overtight-
ening the nut will cause excessive bearing wear.
2005 Touring: Chassis
2-75
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