Harley Davidson 2018 softail models. Service manual — page 8
Special Tools
Description
Part Number
Qty.
DIGITAL TECHNICIAN II
HD-48650
1
NOTICE
This device is sensitive to electrostatic discharge (ESD). To prevent damage to the device, always touch the
motorcycle frame or a grounded surface before handling. (00588c)
1. Install ABS module.
a. See Figure 2. Install bracket (1).
b. Install screws (2). Tighten.
Torque: 10.8-13.5 N·m (96-119 in-lbs) ABS Module
bracket screw
c. Install ABS module (3) with bracket.
d. See Figure 1. Install screw (1). Tighten.
Torque: 10.8-13.5 N·m (96-119 in-lbs) ABS Module
frame screw
e. Install side cover mounting stud (2).
Torque: 8.1-10.8 N·m (72-96 in-lbs) Side cover
mounting stud
f. Install cable straps (3).
g. Connect ABS connector (4).
2. If installing a new ABS module, use DTII for set-up
procedure:
Special Tool: DIGITAL TECHNICIAN II (HD-48650)
a.
Choose the REFLASH icon.
b.
Follow the on-screen prompts.
1
Screw
2
Side cover mounting stud
3
Cable strap (2)
4
Connector
Figure 1. ABS Module
1
Bracket
2
Screw (2)
3
ABS Module
4
ABS module to rear brake line
5
Rear master cylinder to ABS module line
6
ABS module to front brake line
7
Front master cylinder to ABS module line
Figure 2. ABS Module Bracket
WARNING
When any hydraulic brake component, line or connection is loosened or replaced on an ABS motorcycle, Digital
Technician II must be used during the brake bleeding procedure to verify all air is removed from the system. Failure to
properly bleed the brake system could adversely affect braking, which could result in death or serious injury. (00585c)
1. Connect brake lines from ABS module. See Front Brake
Line: Non-ABS.
2. Bleed brake system. See Drain.
3. Connect negative battery cable. See Main Fuse.
4. Install seat. See Remove.
5. Install right side cover. See Remove.
WARNING
After repairing the brake system, test brakes at low
speed. If brakes are not operating properly, testing
at high speeds can cause loss of control, which
could result in death or serious injury. (00289a)
6. Operate motorcycle at low speeds to verify that braking
systems operate properly.
Special Tools
Description
Part Number
Qty.
BASIC VACUUM BRAKE BLEEDER
BB200A
1
NOTICE
DOT 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage.
(00239c)
NOTE
Procedure for draining brake fluid is the same for both the front and the rear brake systems.
For best results, use BASIC VACUUM BRAKE BLEEDER (Part Number:BB200A) to drain the brake systems.
Both front and rear brake systems are affected when removing ABS (Anti-lock braking system) module.
1.
Remove master cylinder reservoir cap of the affected
system.
2.
See Figure 1. Remove cap (1) from bleeder screw (2).
3.
Using vacuum brake bleeder to drain system.
Special Tool: BASIC VACUUM BRAKE BLEEDER
(BB200A)
a. Attach vacuum brake bleeder to a caliper bleeder
screw. Loosen screw 3/4 turn.
b. Operate vacuum bleeder to evacuate all fluid from
master cylinder and line.
c. If needed: Repeat with remaining calipers.
4.
Using brake lever or pedal to drain system.
a. Install end of a length of 7.9 mm (0.31 in) of the ID
(Inside diameter) clear plastic tubing over bleeder
screw.
b. Place free end of tubing in a suitable container.
c. Open bleeder screw one-half turn.
d. Pump brake lever or pedal repeatedly to drain brake
fluid.
5.
Close bleeder screw. Tighten. Torque Specifications
6.
Wipe out any remaining fluid inside master cylinder
reservoir with a clean, lint-free cloth.
1
Cap
2
Bleeder screw
Figure 1. Bleeder Screw (Typical)
Special Tools
Description
Part Number
Qty.
BASIC VACUUM BRAKE BLEEDER
BB200A
1
DIGITAL TECHNICIAN II
HD-48650
1
WARNING
When any hydraulic brake component, line or connection is loosened or replaced on an ABS motorcycle, Digital
Technician II must be used during the brake bleeding procedure to verify all air is removed from the system. Failure to
properly bleed the brake system could adversely affect braking, which could result in death or serious injury. (00585c)
WARNING
Use denatured alcohol to clean brake system components. Do not use mineral-based solvents (such as gasoline or
paint thinner), which will deteriorate rubber parts even after assembly. Deterioration of these components can cause
brake failure, which could result in death or serious injury. (00291a)
CAUTION
Direct contact of DOT 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with
large amounts of water and get medical attention. Swallowing large amounts of DOT 4 brake fluid can cause digestive
discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN.
(00240b)
NOTICE
DOT 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and
protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage.
(00239c)
If DOT 4 brake fluid contacts painted surfaces, IMMEDIATELY flush area with clear water.
NOTICE
Do not allow dirt or debris to enter the master cylinder reservoir. Dirt or debris in the reservoir can cause improper
operation and equipment damage. (00205c)
Verify front brake hand lever and rear brake foot pedal have a firm feel when applied. If not, bleed system as described.
1. Check for moisture content in brake fluid. See Check
Brake Fluid Level.
2.
NOTE
For best results, use BASIC VACUUM BRAKE
BLEEDER (Part Number:BB200A), particularly
if the brake system was drained completely. If a
vacuum brake bleeder is not available, use the
following procedure.
ABS Models: Use DIGITAL TECHNICIAN II
(Part Number:HD-48650) to verify that system
is bled.
Remove bleeder screw cap. Install end of clear plastic
tubing over bleeder screw and place free end in a clean
container.
3.
Position vehicle or handlebar so master cylinder reservoir
is level.
4.
Remove cover from master cylinder reservoir.
WARNING
A plugged or covered relief port can cause brake
drag or lock-up, which could lead to loss of control,
resulting in death or serious injury. (00288a)
5.
Top off the reservoir. Verify proper operation of the master
cylinder relief port by actuating the brake pedal or lever. A
slight spurt of fluid breaks the fluid surface in the reservoir
with internal components are working properly. See
Check Brake Fluid Level.
6.
NOTE
Pay careful attention to fluid level in the master
cylinder reservoir. Add fluid before it empties to avoid
drawing air into the brake lines.
Operate the brake lever or pedal to build hydraulic
pressure.
7.
While holding pressure with the brake lever or pedal:
a. Open bleeder screw about three-quarter turn.
b. Close bleeder screw as soon as the lever or pedal
has moved full range of travel.
c. Allow brake lever or pedal to return slowly to its
released position.
8.
Repeat steps until all air bubbles are purged and a solid
column of fluid is observed in the bleeder tube.
9.
Install bleeder screw cap. Tighten. Refer to Table 1..
10. Check and fill reservoir to specified level. See Check
Brake Fluid Level.
11. ABS Models: Connect DT (Digital technician) and
perform "ABS Service" procedure.
12. Check operation of rear lamps.
WARNING
After repairing the brake system, test brakes at low
speed. If brakes are not operating properly, testing
at high speeds can cause loss of control, which
could result in death or serious injury. (00289a)
13. Test ride motorcycle. Repeat the bleeding procedure if
brakes feel spongy.
Table 1. Torque Specifications
TORQUE
COMPONENT(1)
Bleeder screws
3.9-6.9 N·m (35-61 in-lbs)
Banjo bolts
29-31 N·m (21-23 ft-lbs)
Reservoir cover screws
1-2 N·m (9-18 in-lbs)
(1) Applies to both front and rear brake systems.
1. See Left Side Cover. Remove side cover.
a. Remove screw (1).
b. Pull side cover (2) away to release grommets from mounting studs (3).
1. See Figure 1. Install bracket, if removed.
a. Install bracket (4).
b. Install screw securing bracket to frame. Tighten.
Torque: 0.9-1.1 N·m (8-10 in-lbs) Cover, Left Side,
Bracket to Frame Screw
2. Install side cover.
a. Align side cover (2) with mounting studs (3).
b. Press side cover until fully seated.
c. Install screw (1). Tighten.
Torque: 2.7-4.1 N·m (24-36 in-lbs) Side cover screw
1
Screw
2
Left side cover
3
Mounting stud (2)
4
Bracket
Figure 1. Left Side Cover
1. See Right Side Cover. Remove side cover.
a. Remove screws (1).
b. Pull side cover (2) away to release grommet from mounting stud (3).
1. See Figure 1. Install side cover.
a. Align side cover (2) with mounting stud (3).
b. Press side cover until fully seated.
c. Install screws (1). Tighten.
Torque: 2.7-4.1 N·m (24-36 in-lbs) Side cover
screws
1
Screw (2)
2
Right side cover
3
Mounting stud
Figure 1. Right Side Cover
Fork Oil Seals
The fork oil seal allows a fine film of oil to lubricate the fork sliding surface.
The oil film is more visible after continuous high-speed compression and rebound movement.
Due to greater lubrication needs, larger forks have a greater amount of oil film than smaller forks.
Check Oil Leak
1. Observe oil ring.
2. Wipe fork clean.
3. Ride motorcycle over bumpy road or complete six braking events.
4. See Figure 1. Check fork slider tube for oil.
a. If a normal oil/dust film (1, 2) is present, there is no leak.
b. If an oil run or drip (3) is present, perform procedure two or three more times to confirm oil leak.
1
Normal oil/dust film
2
Normal oil/dust film
3
Drip
Figure 1. Front Forks
1. Remove front wheel. See Prepare.
2. Remove front fender. See Remove.
3. Remove windshield, if equipped. See Remove.
4. Remove front brake caliper(s). See Prepare.
5. FLDE, FLFB, FLFBS, FLHC, FLHCS, FLHCS ANV
Remove rear headlamp nacelle panels. See Prepare.
Remove
1. See Figure 1 or Figure 2. Remove front fork tube
assemblies.
a. Loosen the upper fork bracket pinch screws (1).
b. Loosen the lower fork bracket pinch screws (4).
c. Remove fork tube assemblies (5) from fork brackets
(2, 3).
1
Upper fork bracket pinch bolt (2)
2
Upper fork bracket
3
Lower fork bracket
4
Lower fork bracket pinch bolt (2)
5
Fork tube assembly (2)
Figure 1. Four Pinch Bolt Fork Brackets
1
Upper fork bracket pinch bolt (2)
2
Upper fork bracket
3
Lower fork bracket
4
Lower fork bracket pinch bolt (4)
5
Fork tube assembly (2)
Figure 2. Six Pinch Bolt Fork Brackets
Install
1. See Figure 1. Install front fork tube assemblies.
a. Install fork tube assemblies through lower fork
bracket (8) and upper fork bracket (3).
b. Refer to Table 1. Set installed height (1) at
dimension given and match left and right sides.
c. Tighten lower fork bracket pinch bolt (4). Torque:
21.7-27.1 N·m (16-20 ft-lbs) Lower fork bracket
pinch bolt
NOTE
For models equipped with two lower pinch
bolts per side: Tighten alternately until torque
specification is maintained.
d. Tighten upper fork bracket pinch bolt (1).
Torque: 21.7-27.1 N·m (16-20 ft-lbs) Upper fork
bracket pinch bolt
e. FXBB: Slide upper end of protector (5) up until it
contacts underside of lower fork bracket.
1
Fork tube installed height
Figure 1. Fork Height Dimension Location
Table 1. Front Fork Assembly Dimension
MODEL
DIMENSION
FLDE, FLHC/S
224.0-227.1 mm (8.82-8.94 in)
FLFB/S
227.1-230.1 mm (8.94-9.06 in)
FLSL
213.9-216.9 mm (8.42-8.54 in)
FXBB
200.7-203.7 mm (7.90-8.02 in)
FXBR/S
199.1-202.2 mm (7.84-7.96 in)
FXFB/S
232.4-235.5 mm (9.15-9.27 in)
FXLR
206.8-209.8 mm (8.14-8.26 in)
Special Tools
Description
Part Number
Qty.
FORK TUBE HOLDER
HD-41177
1
FORK SEAL DRIVER
HD-45305
1
FORK OIL LEVEL GAUGE
HD-59000B
1
WARNING
Wear safety glasses or goggles when servicing fork assembly. Do not remove slider tube caps without relieving spring
preload or caps and springs can fly out, which could result in death or serious injury. (00297a)
Disassemble
Initial Disassembly
1. See Figure 1.Clamp fork tube in fork tube holder.
Mount in vise with fork vertical.
Special Tool: FORK TUBE HOLDER (HD-41177)
2. See Figure 2.
a. Remove fork tube plug (1) and O-ring (21).
3.
NOTE
Have a suitable container ready to place spring
assembly into after removal from tube.
Pull spring collar (20), washer (19), and spring (18)
out of fork tube (2).
4. Remove fork assembly from tool.
1
Fork tube holder
2
Fork tube
Figure 1. Fork Tube Holder
1
Fork tube plug
2
Fork tube
3
Lower slider bushing
4
Case cover (FXBR/S/ANX, FXLR)
5
Protector (FXBB)
6
Dust seal
7
Retaining ring
8
Slider oil seal
9
Seal spacer
10
Upper slider bushing
11
Lower stop
12
Slider
13
Washer
14
Screw
15
Damper tube spring
16
Damper tube
17
Damper tube ring
18
Spring
19
Washer
20
Spring collar
21
O-ring
Figure 2. Standard Fork Components
Fork Drain
1.
NOTE
Drain fork oil into a suitable container.
Turn fork assembly upside down to drain fork oil.
a. If only performing a fork oil change, see FORK
FILL later in this procedure. If overhauling the
fork assembly, continue with procedure.
Complete Disassembly
1. Separate slider from fork tube.
NOTE
Since there is little resistance to rotation when
removing socket screw (14), the job is done more
easily with an air impact wrench.
a. Remove screw (14) with washer (13) from the
bottom end of slider (12).
b. FXBR, FXBRS, FXBRS ANX, FXLR: Remove
case cover (4).
c. FXBB: Remove protector (5).
d. Remove dust seal (6).
e. Compress retaining ring (7) and remove from
slider (12).
2.
NOTE
The upper slider bushing (10) is a slight
interference fit in slider (12). The upper bushing,
seal spacer (9) and slider oil seal (8) are
removed together.
Use the fork tube and lower slider bushing (3) as a
slide hammer. Pull the fork tube in a quick continuous
stroke. Continue this slide hammer action until the
components are freed.
3.
Push damper tube (16) and damper tube spring (15)
free of fork tube (2) by inserting a small diameter rod
through the opening in the bottom of tube.
4.
Remove lower stop (11) from the lower end of damper
tube (16).
5.
Damper tube ring (17) can now be removed from the
grooves at the top end of damper tube (16). Do not
remove lower slider bushing (3) unless it requires
replacement.
Clean and Inspect
1. Clean all parts.
2. Inspect parts for wear or damage. Replace parts if
necessary.
3. Inspect OD of slider bushing and ID of fork tube
bushing.
a. If coating is worn through (metallic substrate
showing), replace bushing.
b. Inspect for distortion.
c. If deep scratches or scoring are found, replace
bushing. Also inspect mating components for
similar wear. Replace or repair as necessary.
4. Check fork tube and slider for scoring, scratches and
abnormal wear.
5. Inspect fork tube for nicks from stones and road debris,
especially in area where seal contacts it. Replace if
necessary.
6. See Figure 3. Check runout with a dial indicator.
a. Set fork tube on V-blocks.
b. Replace fork if runout exceeds dimension.
Dimension: 0.2 mm (0.008 in)
Figure 3. Measure Fork Tube Runout
Assemble
Initial Assembly
NOTE
Lubricate all seal lips, quad rings and O-rings with HARLEY DAVIDSON SEAL GREASE during assembly.
1. Install damper tube ring (17). Place damper tube
spring (15) on damper tube (16). Insert damper tube
into fork tube (2).
2. Insert spring (18) into fork tube (2), tapered side
toward damper tube (15), and push bottom of damper
tube through the opening at the bottom end of the
fork tube. Place lower stop (11) over end of damper
tube (16).
3. Apply LOCTITE 565 THREAD SEALANT to screw
(14).
4. Position fork tube (2) and damper tube (16) in slider
(12). Hold the assembly in place by exerting pressure
on the spring. Install socket screw (14) with washer
(13).
5. Tighten screw (14).
Torque: 40-50 N·m (30-37 ft-lbs) Fork damper tube
screw, front
a.
Remove spring (18).
6. Place upper slider bushing (10), seal spacer (9) and a
new slider oil seal (8) (in that order) over fork slider
(2). Verify that the lettered side of the seal is facing
upward.
7. Place fork oil seal installer over fork slider (2). Seat
upper slider bushing (10), seal spacer (9), and slider
oil seal (8) into the slider bore by lightly tapping the
components into place with the installation tool.
Special Tool: FORK SEAL DRIVER (HD-45305)
8. Install retaining ring (7).
9. Install dust seal (6).
a. FXBB: Install protector (5).
b. FXBR, FXBRS, FXBRS ANX, FXLR: Install case
cover (4).
Fork Fill
WARNING
Incorrect amount of fork oil can
adversely affect handling and
lead to loss of vehicle control,
which could result in death or
serious injury. (00298a)
1.
Fill fork tube.
a. Fully compress fork.
b. See Figure 4. Fill with TYPE "E"
HYDRAULIC FORK OIL until oil
level matches specification from
top of fork tube with spring
removed. Adjust oil level to
specification using fork oil level
gauge. Refer to Table 1 Special
Tool: FORK OIL LEVEL GAUGE
(HD-59000B)
Table 1. Oil Level, Front Fork
MODEL
FLUID FILL DIMENSION
FLDE, FLHC, FLHCS, FLSL, FXBB, FXLR
118 mm (4.65 in)
FLFB, FLFBS
106 mm (4.17 in)
FXBR, FXBRS
99 mm (3.90 in)
1
Fork oil level
2
Tube
3
Collar
4
Thumb lock
Figure 4. Oil Level Gauge
Complete Assembly
1. See Figure 2. Install fork spring.
a. Fully extend fork. Install spring (18) with tightly
wound end at bottom.
b. Install washer (19) and spring collar (20).
2. Install fork tube plug.
a. Install new O-ring (2).
b. Install fork tube plug (1). Tighten.
Torque: 30-80 N·m (22-59 ft-lbs) Fork tube plug,
standard
Special Tools
Description
Part Number
Qty.
FORK SEAL DRIVER AND DUST
B-42571
1
BOOT INSTALLER (43MM)
FORK TUBE HOLDER
HD-41177
1
FRONT FORK COMPRESSOR
HD-45966
1
FORK OIL LEVEL GAUGE
HD-59000B
1
Disassemble
Initial Disassembly
NOTICE
Exercise caution to avoid
scratching or nicking fork
tube. Damaging tube can
result in fork oil leaks after
assembly. (00421b)
1.
See Fork Tube Holder.Clamp fork
tube in fork tube holder. Mount in
vise with fork vertical.
Special Tool: FORK TUBE HOLDER
(HD-41177)
2.
See Figure 1 .
a. Remove fork tube plug (1).
b. Compress fork assembly to
expose cartridge damper (15)
rod.
c. Hold nut (10). Remove fork tube
plug (1) from end of damper
rod.
d. Discard O-ring (2).
3.
NOTE
Have a suitable container ready
to place spring into after
removal from assembly.
Remove spring from fork tube.
a. Clamp front fork compressor
vertically in vise with length
adjuster screw topside.
Special Tool: FRONT FORK
COMPRESSOR (HD-45966)
b. Compress fork spring.
c. See Figure 2. Remove nut (1).
d. Release fork spring.
e. See Figure 1. Remove spring
seat stopper (11), spring collar
(12) and spring joint (13).
f. Remove fork assembly from
tool. Remove spring (14).
1
Fork tube plug
2
O-ring
3
Rubber stopper
4
Fork tube
5
Fork tube bushing
6
Seal Spacer
7
Oil seal
8
Retaining ring
9
Dust seal
10
Nut
11
Spring seat stopper
12
Spring collar
13
Spring joint
14
Spring
15
Cartridge damper
16
Centering plate
17
Slider bushing
18
Fork slider
19
Screw
20
Dust cover (FLSB)
Figure 1. Cartridge Fork (Left Side)
1
Locknut
Figure 2. Compress Fork Spring
Fork Drain
1.
NOTE
Drain fork oil into a suitable container.
Drain fork oil.
a. Thread rod extension tool (part of front fork
compressor) onto end of damper rod. Special
Tool: FRONT FORK COMPRESSOR
(HD-45966)
b. Turn fork assembly upside down over drain pan
and slowly pump damper rod at least 20 times
until rod moves freely.
c. If only performing a fork oil change, see FORK
FILL later in this procedure. If overhauling the
fork assembly, continue with procedure.
d. Remove extension tool from damper rod.
Complete Disassembly
1.
See Figure 1. Remove cartridge damper (15).
a. Place fork spring into fork tube.
b. Place fork assembly upside down on a clean shop
rag on the floor.
c. While compressing spring (14) to prevent rotation
of damper, remove screw (19). Use an air impact
wrench for best results.
d. Discard screw.
e. Remove spring (14) and cartridge damper (15)
from fork tube.
2.
NOTE
Do not bend or stretch oil seal retaining ring
during removal.
Remove fork tube.
a. If equipped, separate dust cover (20) from fork
tube (4).
b. Separate dust seal (9) from fork tube.
c. Remove retaining ring (8).
d. Expand fork slider (18) and tube (4) against each
other repeatedly (in a slide-hammer effect) to
remove fork tube.
e. Gently pry at split line to remove slider bushing
(17).
f. Remove fork tube bushing (5), seal spacer (6), oil
seal (7), retaining ring (8), and dust seal (9).
Discard oil seal.
g. If equipped, remove dust cover (20).
3. Remove centering plate (16).
Clean and Inspect
1.
Clean all parts.
2.
Inspect parts for wear or damage. Replace parts if
necessary.
3.
Inspect OD of slider bushing and ID of fork tube
bushing.
a. If coating is worn through (metallic substrate
showing), replace bushing.
b. Inspect for distortion.
c. If deep scratches or scoring are found, replace
bushing. Also inspect mating components for
similar wear. Replace or repair as necessary.
4.
Check fork tube and slider for scoring, scratches and
abnormal wear.
5.
Inspect fork tube for nicks from stones and road debris,
especially in area where seal contacts it. Replace if
necessary.
6.
See Measure Fork Tube Runout. Check runout with a
dial indicator.
a. Set fork tube on V-blocks.
b. Replace fork if runout exceeds dimension.
Dimension: 0.2 mm (0.008 in)
Assemble
Initial Assembly
NOTICE
Exercise caution to avoid scratching or nicking fork tube. Damaging tube can result in fork oil leaks after
assembly. (00421b)
NOTE
Lubricate all seal lips, quad rings and O-rings with HARLEY-DAVIDSON SEAL GREASE during
assembly.
Use FORK TUBE HOLDER (Part Number:HD-41177) as necessary.
Place dust seal with larger diameter end toward top of fork assembly.
Place oil seal with lettering toward top of fork assembly.
1.
See Figure 1. Assemble fork slider.
a. If equipped, install dust cover (20) onto fork slider
(18).
b. Install dust seal (9), retaining ring (8), oil seal (7),
seal spacer (6) and fork tube bushing (5) onto
fork slider.
c. Lightly coat fork slider (18) and slider bushing
(17) with fork oil.
d. Install slider bushing (17). Expand bushing only
enough to fit onto fork slider (18).
e. Install centering plate (16).
f. Install fork slider (18) into fork tube (4).
g. Slide cartridge damper (15) into fork slider (18).
h. Apply LOCTITE 243 MEDIUM STRENGTH
THREADLOCKER AND SEALANT (blue) to new
screw (19).
i.
Install screw (19). Tighten.
Torque: 15-25 N·m (11-18 ft-lbs) Fork, cartridge
screw
2.
Clamp fork slider horizontally in fork tube holder.
Special Tool: FORK TUBE HOLDER (HD-41177)
3.
Install fork oil seal.
a. Install fork tube bushing (5) and seal spacer (6).
b. Assemble fork seal driver and dust boot installer
(43mm) in front of oil seal (7). Long end of tool
faces oil seal.
Special Tool: FORK SEAL DRIVER AND DUST
BOOT INSTALLER (43MM) (B-42571)
c. Drive oil seal into fork tube until seated.
d. Install retaining ring (8).
e. Tap dust seal (9) into place.
f. If equipped rotate dust cover (20) to match any
removal burrs in slider. Tap dust cover into place.
Fork Fill
WARNING
Incorrect amount of fork oil can
adversely affect handling and
lead to loss of vehicle control,
which could result in death or
serious injury. (00298a)
1.
Fill fork tube.
a. Install damper rod extension
tool.
b. Fill with TYPE "E" HYDRAULIC
FORK OIL until it is
approximately 50.8 mm (2.0 in)
from top of fork tube.
c. Pump fork slider ten times to
remove air from system.
d. See Oil Level Gauge. Fully
compress fork. Measure oil level
from top of fork tube with spring
removed. Adjust oil level to
specification using fork oil level
gauge. Refer to Oil Level, Left
Fork.
Special Tool: FORK OIL LEVEL
GAUGE (HD-59000B)
Oil Level, Left ForkMODELFLUID FILL DIMENSIONFLSBFXFB, FXFBS
Complete Assembly
1.
Clamp fork slider vertically in fork tube holder.
Special Tool: FORK TUBE HOLDER (HD-41177)
2.
See Figure 1. Install fork spring.
a. Fully extend fork. Install spring (14) with tightly
wound end at bottom.
b. Install spring joint (13) and spring collar (12).
c. Compress fork using front fork compressor.
Special Tool: FRONT FORK COMPRESSOR
(HD-45966)
d. Install spring seat stopper (11).
e. Install nut (10) so that there is 14 mm (½ in)
between top of nut and top of damper shaft.
3.
Install fork tube plug.
a. Install new O-ring (2).
b. Install rubber stopper (3).
c. Install fork tube plug (1) onto damper (15).
Tighten.
Torque: 17.5-22.5 N·m (13-16 ft-lbs) Fork tube
plug to damper nut
d. Install fork tube plug onto fork tube (4). Tighten.
Torque: 29-39 N·m (22-28 ft-lbs) Fork tube plug
Special Tools
Description
Part Number
Qty.
FORK SEAL DRIVER AND DUST
B-42571
1
BOOT INSTALLER (43MM)
FORK TUBE HOLDER
HD-41177
1
INNER FORK NUT
HD-47852
1
REMOVER/INSTALLER
FORK OIL LEVEL GAUGE
HD-59000B
1
Disassemble
Initial Disassembly
NOTICE
Exercise caution to avoid
scratching or nicking fork
tube. Damaging tube can
result in fork oil leaks after
assembly. (00421b)
1.
See Fork Tube Holder. Clamp fork
tube in fork tube holder. Mount in
vise with fork vertical.
Special Tool: FORK TUBE HOLDER
(HD-41177)
2.
See Figure 1.
a. Remove fork tube plug (1).
b. Compress fork assembly to
expose joint rod (7).
c. Hold nut (5). Remove fork tube
plug (1) from end of joint rod.
d. Discard O-ring (2).
3.
NOTE
Have a suitable container ready
to place spring assembly into
after removal from tube.
Remove spring assembly from fork
tube.
a. Using inner fork nut
remover/installer remove inner
fork nut (6).
Special Tool: INNER FORK
NUT REMOVER/INSTALLER
(HD-47852)
b. Remove nut (5) and joint rod (7).
c. Remove spring collar (8),
washer (9) and spring (10).
d. Remove fork assembly from
tool.
1
Fork tube plug
2
O-ring
3
Rubber stopper
4
Fork tube
5
Nut
6
Inner fork nut
7
Joint rod
8
Spring collar
9
Washer
10
Spring
11
Slider bushing
12
Fork tube bushing
13
Seal spacer
14
Oil seal
15
Retaining ring
16
Dust seal
17
Dust cover (FLSB)
18
Fork slider
19
Screw
Figure 1. Front Fork (Right Side)
Fork Drain
1.
NOTE
Drain fork oil into a suitable container.
Turn fork assembly upside down to drain fork oil.
a. If only performing a fork oil change, see FORK
FILL later in this procedure. If overhauling the
fork assembly, continue with procedure.
Complete Disassembly
1. See Fork Tube Holder. Clamp fork tube in fork tube
holder. Mount in vise with fork vertical.
Special Tool: FORK TUBE HOLDER (HD-41177)
2. Remove fork tube.
NOTE
Do not bend or stretch oil seal retaining ring
during removal.
a. If equipped, separate dust cover (17) from fork
tube (4).
b. Separate dust seal (16) from fork tube.
c. Remove retaining ring (15).
d. Expand fork slider (18) and fork tube (4) against
each other repeatedly (in a slide-hammer effect)
to remove fork tube.
e. Gently pry at split line to remove fork tube
bushing (12).
f. Remove slider bushing (11), seal spacer (13), oil
seal (14), retaining ring (15), and dust seal (16)
from fork slider. Discard oil seal.
g. If equipped, remove dust cover (17).
Clean and Inspect
1.
Clean all parts.
2.
Inspect parts for wear or damage. Replace parts if
necessary.
3.
Inspect OD of slider bushing and ID of fork tube
bushing.
a. If coating is worn through (metallic substrate
showing), replace bushing.
b. Inspect for distortion.
c. If deep scratches or scoring are found, replace
bushing. Also inspect mating components for
similar wear. Replace or repair as necessary.
4.
Check fork tube and slider for scoring, scratches and
abnormal wear.
5.
Inspect fork tube for nicks from stones and road debris,
especially in area where seal contacts it. Replace if
necessary.
6.
See Measure Fork Tube Runout. Check runout with a
dial indicator.
a. Set fork tube on V-blocks.
b. Replace fork if runout exceeds dimension.
Dimension: 0.2 mm (0.008 in)
Assemble
Initial Assembly
NOTICE
Exercise caution to avoid scratching or nicking fork tube. Damaging tube can result in fork oil leaks after
assembly. (00421b)
NOTE
Lubricate all seal lips, quad rings and O-rings with HARLEY-DAVIDSON SEAL GREASE during
assembly.
Use FORK TUBE HOLDER (Part Number:HD-41177) as necessary.
Place dust seal with larger diameter end toward top of fork assembly.
Place oil seal with lettering toward top of fork assembly.
1.
See Figure 1. Assemble fork slider.
a. If equipped, place dust cover (17) onto fork slider
(18).
b. Place dust seal (16), retaining ring (15), oil seal
(14), seal spacer (13) and slider bushing (11)
onto fork slider.
c. Install fork tube bushing (12). Expand bushing
only enough to fit onto fork slider (18).
d. Lightly coat fork slider (18) and fork tube bushing
(12) with fork oil.
e. Install fork slider (18) into fork tube (4).
2.
Clamp fork slider horizontally in fork tube holder.
Special Tool: FORK TUBE HOLDER (HD-41177)
3.
Install fork oil seal.
a. Install slider bushing (11) and seal spacer (13).
b. Assemble fork seal driver and dust boot installer
(43mm) in front of oil seal (14). Long end of tool
faces oil seal.
Special Tool: FORK SEAL DRIVER AND DUST
BOOT INSTALLER (43MM) (B-42571)
c. Drive oil seal into fork tube until seated.
d. Install retaining ring (15).
e. Install dust seal (16).
f. Tap dust seal into place.
g. If equipped, install dust cover (17).
h. Rotate dust cover to match any removal burrs in
slider. Tap dust cover into place.
Fork Fill
WARNING
Incorrect amount of fork oil can
adversely affect handling and
lead to loss of vehicle control,
which could result in death or
serious injury. (00298a)
1.
Fill fork tube.
a. Fully compress fork.
b. See Oil Level Gauge. Fill with
TYPE "E" HYDRAULIC FORK
OIL until oil level matches
specification from top of fork
tube with spring removed. Adjust
oil level to specification using
fork oil level gauge. Refer to
Table 1.
Table 1. Oil Level, Right Fork
MODEL
FLUID FILL
DIMENSION
FLSB
140 mm (5.5 in)
FXFB,
141 mm (5.6 in)
FXFBS
Special Tool: FORK OIL LEVEL
GAUGE (HD-59000B)
Complete Assembly
WARNING
Wear safety glasses or goggles when servicing fork assembly. Do not remove slider tube caps without
relieving spring preload or caps and springs can fly out, which could result in death or serious injury. (00297a)
1. See Figure 1. Install fork spring.
a. Fully extend fork. Install spring (10) with tightly
wound end at bottom.
b. Install washer (9) and spring collar (8).
c. Install nut (5) and joint rod (7).
d. Using inner fork nut remover/installer install inner
fork nut (6).
Special Tool: INNER FORK NUT
REMOVER/INSTALLER (HD-47852)
e. Tighten inner fork nut.
Torque: 93-113 N·m (69-83 ft-lbs) Fork, right,
inner fork nut
2. Install fork tube plug.
a. Install new O-ring (2).
b. Install rubber stopper (3).
c. Install fork tube plug (1) onto joint rod (7).
Tighten.
Torque: 17.5-22.5 N·m (13-16 ft-lbs) Fork tube
plug to damper nut
d. Install fork tube plug onto fork tube (4). Tighten.
Torque: 30-40 N·m (22-30 ft-lbs) Fork tube plug
1. FLDE, FLFB, FLFBS, FLHC, FLHCS, FLHCS ANV:
Install rear headlamp nacelle panels. See Prepare.
2. Install front brake caliper(s). See Prepare.
3. Install windshield, if equipped. See Remove
4. Install front fender. See Remove.
5. Install front wheel. See Prepare.
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