FRONT SUSPENSION AND STEERING
431
shield onto the steering stem before installing the
1. Wipe the bearing races with a solvent-soaked rag
steering stem in the frame. If necessary, install the
and then dry with compressed air or a lint-free cloth.
lower bearing as described in this chapter.
Check the races in the steering head for pitting,
4. Insert the steering stem into the frame and hold it
scratches, galling or excessive wear. If any of these
firmly in place.
conditions exist, replace the races as described in
5. Install the upper bearing over the fork stem and
this chapter. If the races are good, wipe each race
seat it into to the upper race. Install the upper dust
with grease.
shield.
2. Clean the bearings in solvent to remove all of the
old grease. Blow the bearing dry with compressed
CAUTION
air, making sure not to allow the air jet to spin the
Do not overtighten the adjust nut in
bearing. Do not remove the lower bearing from the
Step 6 or the bearings and races will be
fork stem unless it is to be replaced. Clean the bear-
damaged. Final adjustment of the fork
ing while installed in the steering stem.
stem will take place after the front
3. After the bearings are dry, hold the inner race
wheel is installed on the motorcycle.
with one hand and turn the outer race with the other
6. Thread the adjust nut onto the steering stem.
hand. Turn the bearing slowly, the bearing must turn
Tighten the adjust nut until the steering stem can be
smoothly with no roughness. Visually check the
turned from side to side with no noticeable axial or
bearing for pitting, scratches or visible damage. If
lateral play. The steering stem must turn with no
the bearings are worn, check the dust covers for
binding or roughness.
wear or damage or for improper bearing lubrication.
7. Install the upper fork bracket over the steering
Replace the bearing if necessary. If a bearing is go-
stem.
ing to be reused, pack it with grease and wrap it with
8. Install a new lockwasher over the steering stem.
wax paper or some other type of lint-free material
Engage the lockwasher pin into the hole in the up-
until it is reinstalled. Do not store the bearings for
per fork bracket. Then install the steering stem nut.
any length of time without lubricating them or they
10
Tighten the steering stem nut securely.
will rust.
9. Install the front fork legs as described in this
4. Check the steering stem for cracks or damage.
chapter.
Check the threads at the top of the stem for damage.
10. Install the handlebar and tighten the clamp
Check the steering stem bolt or nut for damage.
bolts as described under Handlebar Removal/In-
Thread it into the steering stem; make sure the bolt
stallation in this chapter.
threads easily with no roughness.
11. Install the headlight mounting bracket onto the
5. Replace all worn or damaged parts. Replace
fork bracket. Tighten the mounting bolts securely.
bearing races as described in this chapter.
12. Install the brake hose bracket onto the bottom
6. Replace the lower steering stem bearing and the
of the lower fork bracket. Tighten the brake hose
dust shield as described in this chapter.
bracket bolt to the specification in Table 1.
7. Check for broken welds on the frame around the
13. Install the front wheel as described in Chapter
steering head. If any are found, have them repaired
Nine.
by a competent frame shop or welding service fa-
14. Adjust the steering play as described under
miliar with motorcycle frame repair.
Steering Play Adjustment in this chapter.
15. Tighten the steering stem nut to the specifica-
STEERING HEAD BEARING RACE
tion in Table 1. Bend the lockwasher tab against
REPLACEMENT
one nut flat.
16. Install the cap onto the steering stem nut.
The upper and lower bearing outer races are
pressed into the frame. Do not remove the bearing
Inspection
races unless replacement is necessary. If removed,
(All Models)
replace both the outer race along with the bearing at
the same time. Never reinstall an outer race that has
The bearing outer races are pressed into the steer-
been removed as it is no longer true and will dam-
ing head.
age the bearing if reused.
432
CHAPTER TEN
1. Remove the steering stem as described in this
chapter.
93
2. To remove a race, insert an aluminum or brass
rod into the steering head and carefully tap the race
out from the inside (Figure 93). Tap all around the
race so that neither the race nor the steering head is
bent.
3. Clean the steering head with solvent and dry
thoroughly.
4A. Install the bearing races with a steering head
bearing race installer tool (JIMS part No. 1725), fol-
lowing the manufacturer’s instructions.
4B. If the special tools are 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.
Make sure not to contact the bearing race sur-
faces. See Figure 94. Drive the race into the
steering head until it bottoms out on the bore
shoulder.
c. Repeat to install the lower race into the steer-
ing head.
5. Apply bearing grease to the face of each race.
94
Fork Stem Lower Bearing Replacement
Do not remove the steering stem lower bearing
and lower seal unless it is going to be replaced. The
lower bearing can be difficult to remove. If the
lower bearing cannot be removed as described in
this procedure, take the steering stem to a
Harley-Davidson dealership and have them remove
it and reinstall a new part.
Never reinstall a lower bearing that has been re-
moved as it is no longer true and will damage the
rest of the bearing assembly if reused.
Wood
1. Install the steering stem bolt onto the top of the
block
steering stem to protect the threads.
2. Loosen the lower bearing from the shoulder at
the base of the steering stem with a chisel as shown
Race
in Figure 95. Slide the lower bearing and grease
seal off the steering stem.
3. Clean the steering stem with solvent and dry
Head
tube
thoroughly.
4. Position the new lower dust seal with the flange
side facing up.
-------------------------------------------------------------------------------------------------------------------------------------------------------------
FRONT SUSPENSION AND STEERING
433
95
Stem nut
96
Steering stem
Chisel
Hollow pipe
Bearing
Dust seal and bottom race
5. Slide a new grease seal and the lower bearing
3. Apply a strip of masking tape across the front
onto the steering stem until it stops on the raised
end of the front fender. Draw a vertical line across
shoulder.
the tape at the center of the fender.
4. Turn the handlebar so that the front wheel faces
6. Align the lower bearing with the machined
straight ahead.
shoulder on the steering stem. Press or drive the
5. Install a pointer so the base is stationary on the
lower bearing onto the steering stem until it bottoms
floor and the pointer indicates the center of the fender
(Figure 96).
tape mark when the wheel is facing straight ahead.
6. Loosen the lower bracket pinch bolt on both fork
tubes.
STEERING PLAY ADJUSTMENT
7. Lightly push the fender toward the right side un-
til the front end starts to turn by itself. Mark this
1. Support the motorcycle with the front wheel off
point on the tape.
10
the ground. See Motorcycle Stands in Chapter Nine.
8. Repeat Step 6 for the left side.
2. On models so equipped, remove the windshield,
9. Measure the distance between the 2 marks on the
as described in Chapter Thirteen, and all other ac-
tape. The correct distance is 1-2 in. (25-50 mm). If
cessory weight from the handlebar and front fork
the distance is incorrect, perform Step 10.
that could affect this adjustment.
10. Loosen or tighten the steering stem nut or bolt
until the measurement is within the limits.
NOTE
11. Tighten the lower fork bracket pinch bolts to
If a control cable affects handlebar
the torque specification in Table 1.
movement, disconnect it.
12. Reinstall all parts previously removed.
Table 1 FRONT SUSPENSION TORQUE SPECIFICATIONS
Item
ft.-lb.
in.-lb.
N·m
Fork cap FXDX, FXDXT
22-29
-
30-39
Fork cap screw FXDX,
FXDXT
22-29
-
30-39
Fork slider tube cap
FXDWG
11-22
-
15-30
All models
except FXDWG
11-22
-
15-30
Upper fork bridge
pinch bolt
FXDWG
21-27
-
29-37
(continued)
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434
CHAPTER TEN
Table 1 FRONT SUSPENSION TORQUE SPECIFICATIONS (continued)
Item
ft.-lb.
in.-lb.
N·m
Upper and lower fork
bracket pinch bolts
All models
except FXDWG
25-30
-
34-41
Steering stem
Bolt (all models
except FXDWG)
21-27
-
29-37
Nut (FXDWG)
35-40
-
47-54
Brake hose bracket bolt
-
132
15
Front fender nuts
FXDWG
15-21
-
20-28
All models
except FXDWG
-
120-168
14-19
Table 2 FRONT FORK OIL CAPACITY AND OIL LEVEL DIMENSIONS
Model
Capacity oz. (ml)
Oil level dimension
1999 models
FXDWG
10.2 (302)
-
All models except FXDWG
9.2 (272)
-
2000-on models
FXD
10.6 (314)
6.69
(169.9)
FXDS-CONV
11.5 (341)
6.10
(154.9)
FXDWG
12.0 (356)
7.28
(184.9)
FXDX, FXDXT
See text procedure
FXDP
NA
2000-2001
FXDL
10.7 (316)
7.20
(182.0)
2002-on
FXDL
10.6 (304)
6.69
(169.9)
NA = Information not available from the manufacturer.
Table 3 FRONT FORK SPECIFICATIONS (FXDXT AND 2000-ON FXDX)*
Fork spring minimum length
17.0 in. (431.8 mm)
Fork tube maximum runout
0.008 in. (0.2 mm)
*Service specifications for all other fork assemblies are not available from the manufacturer.
-------------------------------------------------------------------------------------------------------------------------------------------------------------
CHAPTER ELEVEN
REAR SUSPENSION
11
This chapter describes repair and replacement
SHOCK ABSORBERS
procedures for the rear suspension components. Re-
fer to Table 1 at the end of this chapter for torque
The shock absorbers are spring controlled and hy-
specifications.
draulically damped. Spring preload is adjustable on
all models and the rebound compression is also ad-
justable on FXDX and FXDXT models. Refer to
WARNING
Shock Absorber Adjustment in this chapter.
All nuts and bolts used on the rear
suspension must be replaced with
parts of the same type. Do not use a
Removal/Installation
replacement part of lesser quality or
substitute design, as it may affect the
When servicing the rear shocks, remove one
performance of the rear suspension or
shock at a time. If it is necessary to remove both
fail, leading to loss of control of the
shocks, support the motorcycle with the rear wheel
motorcycle. The torque specifications
off the ground.
listed in Table 1 must be used during
installation to ensure proper retention
1. Support the motorcycle with the rear wheel off
of these components.
the ground. See Motorcycle Stands in Chapter Nine.
-------------------------------------------------------------------------------------------------------------------------------------------------------------
436
CHAPTER ELEVEN
1
2
2. Place wooden blocks under the rear wheel to
place the rear wheel in a neutral position with no
3
strain on the shock absorber mounting hardware.
3A. On FXDX and FXDXT models, perform the
following:
a. Remove the upper acorn nut and washer (A,
Figure 1) securing the shock absorber to the
frame shock stud.
b. Remove the lower acorn nut and washer (B,
Figure 1) securing the shock absorber to the
swing arm mounting bracket.
c. Pull the shock absorber straight off the frame
upper stud and remove the shock absorber.
3B. On all models except FXDX and FXDXT, per-
4
form the following:
a. Remove the upper acorn nut and washer (A,
Figure 2) securing the shock absorber to the
frame shock stud.
b. Remove the lower acorn nut and washer (Fig-
ure 3) securing the shock absorber to the
swing arm mounting bracket.
c. On models so equipped, remove the chrome
cover (B, Figure 2).
d. Pull the shock absorber straight off the frame
upper stud and remove the shock absorber.
4. Check the upper shock stud (Figure 4) for loose-
ness. Securely tighten if necessary.
5
5. Repeat for the other shock absorber if necessary.
6. Inspect the shock absorber as described in this
chapter.
7. Install the shocks by reversing these removal
steps while noting the following:
a. Apply a few drops of ThreeBond TB1342 or
an equivalent to the shock stud and bolt
threads.
b. Install the washers and nuts and tighten to the
specification in Table 1.
-------------------------------------------------------------------------------------------------------------------------------------------------------------
REAR SUSPENSION
437
6
10
c. Adjust the shock absorbers as described in
7
this chapter.
d. Lower the motorcycle and test ride it to make
sure the rear suspension is working properly.
Inspection
(FXDX and FXDXT Models)
There are no shock replacement parts available
for these models. If any part other than the mount-
ing hardware is damaged, replace the shock assem-
bly.
1. Remove the shock absorber as described in this
chapter.
8
2. Inspect the upper shock bushing (Figure 5) and
11
lower shock bushing (Figure 6) for wear and deteri-
oration.
3. Inspect the shock absorber. If the damper hous-
ing (A, Figure 7) is leaking, bent, or in any way
damaged, replace the shock absorber.
4. Inspect the shock spring (B, Figure 7), spring re-
tainer, cover and spring adjust cam for cracks or
damage.
5. Note the existing setting of the rebound adjuster.
6. Rotate the rebound adjuster (Figure 8) through
all of its ten settings. Make sure the adjuster rotates
freely and engages the detent in each position. Re-
9
turn the adjuster to the setting noted in Step 5.
Inspection
(All Models Except FXDX and FXDXT)
1. Remove the shock absorber as described in this
chapter.
2. Inspect the upper shock bushing (A, Figure 9)
and lower shock bushing (A, Figure 10) for wear and
deterioration. Replace worn or damaged bushings.
-------------------------------------------------------------------------------------------------------------------------------------------------------------
438
CHAPTER ELEVEN
11
12
REAR SHOCK ABSORBER
3. Inspect the shock absorber. If the damper hous-
ing (A, Figure 11) is leaking, bent, or in any way
damaged, replace the shock absorber.
4. Inspect the shock spring (B, Figure 11), spring
retainer, cover and cam for cracks or damage. If
necessary, replace the shock spring as described in
this section.
Shock Bushing Inspection and Replacement
(All Models Except FXDX and FXDXT)
Refer to Figure 12.
Replace both bushings at the same time.
1. Remove the shock absorber as described in this
chapter.
CAUTION
When supporting the shock absorbers
in a press in Step 2, position the press
blocks or other equipment so that they
do not dent or otherwise damage the
damper body.
2. Support the shock absorber in a press and press
1.
Spring retainer
2.
Upper case
out the bushing.
3.
Spring
3. Repeat for the bushing on the other end.
4.
Spring guide
4. Clean the shock eyelets of all rust and rubber res-
5.
Spring adjuster cam
6.
Cam sleeve
idue. Then check the eyelets for cracks, burrs, dents
7.
Nut
and other problems. Replace the shock absorber if
8.
Lockwasher
damaged.
9.
Washer
10.
Bolt (frame mount)
NOTE
11.
Bushing
The upper and lower shock bushings
12.
Shock cover
are identical.
13.
Acorn nut
14.
Bolt
15.
Screw
5. Align the new bushing with the shock eyelet and
16.
Damper housing
start it into place. Then support the shock absorber
in a press and press the bushing into place, centering
-------------------------------------------------------------------------------------------------------------------------------------------------------------
REAR SUSPENSION
439
retainer to fly off, causing severe per-
13
sonal injury.
4. Compress the spring and remove the spring re-
tainer (B, Figure 9). Then release spring tension
and remove the shock absorber from the tool. Com-
plete the disassembly by removing the parts in the
order shown in Figure 12.
5. Spring free length specifications are not avail-
able. If the spring has sagged, remove the other
shock spring and compare the length of both
springs. Replace both springs if one is shorter than
the other one.
6. Inspect the spring adjuster for cracks, excessive
14
wear or other damage.
7. Assemble by reversing these disassembly steps,
while noting the following:
a. Make sure the spring retainer (B, Figure 9) is
seated correctly in the cover (C, Figure 9) be-
fore releasing the pressure of the spring com-
pressor tool.
b. Adjust the spring pre-load as described in this
chapter.
it in the shock eyelet. Repeat for the bushing in the
SHOCK ABSORBER ADJUSTMENT
other end.
11
Spring Preload Adjustment
Spring Removal/Installation
(All Models Except FXDX and FXDXT)
The ride height (height of a motorcycle at rest
with no rider or passenger) can be adjusted with the
A spring compressor is required to remove and
cam preload adjuster at the base of each shock
install the shock spring. When servicing aftermar-
spring (B, Figure 10). Turning the cam adjuster to
ket shocks, follow the manufacturer’s instructions.
the five different steps moves the cam ramps up or
Refer to Figure 12.
down, either compressing or extending the spring.
1. Remove the shock absorber as described in this
Increasing the cam angle increases the spring load
chapter.
and raises the ride height. Spring preload also con-
2. Rotate the spring adjuster cam to the lowest set-
trols how far the shock absorber compresses under
ting to reduce the amount of spring pressure on the
the weight of the motorcycle and rider.
shock absorber.
Select the position that best suits the vehicle load
3. Mount the shock absorber in a spring compres-
requirements. The cam positions range from the No.
sor tool (Figure 13).
1 for a rider with no luggage to the No. 5 consisting
of the maximum allowable GVWR loads listed in
WARNING
the owner’s manual. The standard factory setting is
Do not attempt to remove the spring
the third cam step position.
from the shock absorber without a
Rotate the cam
(Figure
14) with a spanner
spring compressor. Because the
spring is under considerable pres-
wrench to compress the spring (heavy loads) or ex-
sure, using makeshift tools or incor-
tend the spring (light loads). Set the cam on both
rect procedures may allow the spring
shock absorbers to the same preload position.
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