| | | ------------------------------------------------------------------------------------------------------------------------------------------------------------- 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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