Harley Davidson Softail 2000-2005. Service manual — page 25

FRONT SUSPENSION AND STEERING (TELESCOPIC FRONT FORK)

427

STEERING STEM (FLSTC AND FLSTF)

1. Clip nut
2. Back panel (left side)
3. Clamp
4. Screw
5. Locknut
6. Bolt
7. Steering stem cap
8. Steering stem bolt
9. Washer

10. Upper bracket
11. Upper dust seal
12. Upper bearing
13. Upper and lower bearing

14. Lower bearing
15. Bracket
16. Lockwasher
17. Back panel (right side)
18. Trim strip
19. Steering stem/lower bracket
20. Fork cap bolt
21. Front trim panel
22. Spacer
23. Oil seal
24. Lockwasher
25. Fork tube cover
26. Snap ring

14. Remove the upper dust shield and bearing from the
steering head.
15. Inspect the steering stem and bearing assembly as de-
scribed under

Inspection (All Models)

in this section.

Installation
(FLSTC and FLSTF Models)

new

washer and the steering

stem bolt. Tighten the steering stem bolt finger-tight at
this time.
8. Install the fork tube covers, lockwashers and screws.
Tighten the screws securely.
9. Install the front fork legs as described in this chapter.

CAUTION

Do not overtighten the steering stem bolt in
Step 9 or damage will occur to the bearings
and races. Final adjustment of the fork stem
will take place after the front wheel is in-
stalled.

10. Tighten the steering stem bolt until the steering
stem/lower bracket can be turned from side to side with no
axial or lateral play. When the play feels correct, tighten
the steering stem bolt to 97-124 in.-lb. (11-14 N•m).
11. Install the steering stem cap.
12. Install the front brake hose to the bottom of the lower
fork bracket and tighten the bolt securely.
13. Install the three front and back trim panels to the fork
brackets. Tighten the screws and nuts securely.
14. Install the headlight bracket and headlight as de-
scribed in Chapter Eight.
15. Install the handlebar as described in this chapter.
16. Install the front fender and front wheel as described in
Chapter Nine.
17. Install the fuel tank as described in Chapter Seven.
18. On FLSTC models, install the windshield as de-
scribed in Chapter Fourteen.
19. Adjust the steering play as described under

Steering

Play Adjustment

in this chapter.

428

CHAPTER TEN

STEERING STEM (FXSTD)

9. Lower bearing race

10. Lower bearing
11. Lower dust shield
12. Steering stem/

lower bracket

13. Bolt
14. Lockwasher
15. Snap ring

1. Steering stem cap
2. Steering stem nut
3. Lockwasher
4. Upper bracket
5. Adjusting nut
6. Upper dust seal
7. Upper bearing
8. Upper bearing race

Removal
(FXSTD, FXST and FXSTB Models)

Refer to Figure 56 and Figure 57.

1. Remove the fuel tank as described in Chapter Seven.
2. Remove the front fender and front wheel as described
in Chapter Nine.
3. Remove both front fork legs as described in this chapter.
4. Unscrew and remove the steering stem cap (Figure 58).
5. Remove the bolt securing the front brake hose (A, Fig-
ure 59) assembly to the bottom of the lower fork bracket.
Do not disconnect any brake hose connections.
6. Remove the handlebar (A, Figure 60) as described in
this chapter.
7. Remove the headlight and headlight bracket (B, Fig-
ure 60) as described in Chapter Eight.
8. Pry the tab on the lockwasher away from the steering
stem nut.
9. Remove the steering stem nut (C, Figure 60) and
lockwasher. Discard the lockwasher.
10. Remove the upper fork bracket (D, Figure 60).

CAUTION

Hold or secure the steering stem to keep it
from falling after removal of the bearing ad-
justing nut in Step 11.

FRONT SUSPENSION AND STEERING (TELESCOPIC FRONT FORK)

429

STEERING STEM

(FXST AND FXSTB)

1. Steering stem cap
2. Steering stem nut
3. Lockwasher
4. Upper bracket
5. Bolt
6. Adjusting nut
7. Upper dust seal
8. Upper bearing
9. Upper bearing race

10. Lower bearing race

11. Lower bearing
12. Lower dust shield
13. Steering stem/

lower bracket

14. Lockwasher
15. Bolt
16. Cover
17. Pad
18. Snap ring

11. Loosen and remove the bearing adjusting nut, then
slide the steering stem/lower bracket (B, Figure 59) out of
the steering head.
12. Remove the upper dust shield and bearing from the
steering head.
13. Inspect the steering stem and bearing assembly as de-
scribed under

Inspection (All Models)

in this section.

Installation
(FXSTD, FXST and FXSTB Models)

1. If the steering head bearing races were replaced, make
sure they are seated in the steering head.
2. Wipe the bearing races with a clean, lint-free cloth.
Then lubricate each race with bearing grease.
3. Pack the upper and lower bearings with bearing grease.
4. If removed, install the lower dust shield and the lower
bearing on the steering stem/lower bracket as described in
this chapter.
5. Insert the steering stem/lower bracket (B, Figure 59)
into the frame steering head and hold it firmly in place.
6. Install the upper bearing over the steering stem and
seat it into to the upper race. Install the upper dust shield.
7. Install the bearing adjusting nut and tighten until the
steering stem/lower bracket can be turned from side to
side with no axial or lateral play. When the play feels cor-
rect, tighten the bearing adjusting nut securely.
8. Install the upper bracket (D, Figure 60).
9. Install the

new

lockwasher and engage its pin with the

hole in the upper bracket. This is necessary to keep the
lockwasher from rotating.
10. Install the steering stem nut (C, Figure 60). Tighten
the steering stem nut finger-tight at this time.
11. Install the front fork legs as described in this chapter.

CAUTION

Do not overtighten the steering stem nut in
Step 12 or damage will occur to the bear-
ings and races. Final adjustment of the fork
stem will take place after the front wheel is
installed.

12. Tighten the steering stem nut until the steering
stem/lower bracket can be turned from side to side with no
axial or lateral play. When the play feels correct, tighten
the steering stem nut to 50-65 ft.-lb. (68-88 N•m).
13. Bend the tab on the lockwasher up against the flats on
the steering stem nut.
14. Install the steering stem cap (Figure 58) and tighten
securely.
15. Install the front brake hose assembly (A, Figure 59)
onto the bottom of the lower fork bracket and tighten the
bolt securely.

16. Install the headlight bracket and headlight (B, Figure
60) as described in Chapter Eight.

17. Install the handlebar (A, Figure 60) as described in
this chapter.

18. Install the front fender and front wheel as described in
Chapter Nine.

19. Install the fuel tank as described in Chapter Seven.

20. Adjust the steering play as described under

Steering

Play Adjustment

in this chapter.

430

CHAPTER TEN

Inspection (All Models)

The bearing outer races are pressed into the steering

head. Do not remove them unless they are going to be re-
placed.
1. Wipe the bearing races with a solvent-soaked rag and
dry them with compressed air or a lint-free cloth. Check
the races in the steering head (Figure 61) for pitting,
scratches, galling or excessive wear. If any of these condi-
tions exist, replace the races as described in this chapter. If
the races are in good condition, wipe each race with
grease.
2. Clean the bearings in solvent to remove all of the old
grease. Blow the bearing dry with compressed air, making
sure not to allow the air jet to spin the bearing. Do not re-

move the lower bearing from the fork stem unless it is to
be replaced. Clean the bearing while it is installed in the
steering stem.
3. After the bearings are dry, hold the inner race with one
hand and turn the outer race with the other hand. Turn the
bearing slowly. The bearing should turn smoothly with no
roughness. Visually check the bearing (Figure 62) for pit-
ting, scratches or visible damage. If the bearings are worn,
check the dust covers for wear or damage, or for improper
bearing lubrication. Replace the bearing if necessary. If a
bearing is going to be reused, pack it with grease and wrap
it with wax paper or another lint-free material until it is re-
installed. Do not store the bearings for any length of time
without lubricating them to prevent rust.
4. Check the steering stem/lower bracket for cracks or
damage. Check the threads at the top of the stem for dam-
age. Check the steering stem bolt or nut for damage and
thread it into the steering stem. Make sure the bolt or nut
threads easily with no roughness.
5. Replace all worn or damaged parts. Replace bearing
races as described in this chapter.
6. Replace the lower steering stem bearing (Figure 63)
and the dust shield as described in this chapter.
7. Check for broken welds on the frame around the steer-
ing head. If any are found, have them repaired by a com-
petent frame shop or welding service familiar with
motorcycle frame repair.

STEERING HEAD BEARING RACE

REPLACEMENT

The upper and lower bearing outer races are pressed

into the frame. Do not remove the bearing races unless re-
placement is necessary. If they are removed, replace both
the outer race and bearing at the same time. Never rein-
stall an outer race that has been removed as it is no longer
true and will damage the bearing.
1. Remove the steering stem as described in this chapter.
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 64). Tap all around the race so neither the
race nor the steering head is bent.
3. Clean the steering head with solvent and dry it thor-
oughly.
4A. Install the bearing races with the steering head bear-
ing race installer tool (JIMS part No. 1725) following the
manufacturer’s instructions.
4B. If the special tools are not available, install the bear-
ing 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. Do not con-

FRONT SUSPENSION AND STEERING (TELESCOPIC FRONT FORK)

431

tact the bearing race surfaces. See Figure 65. Drive
the race into the steering head until it bottoms on the
bore shoulder.

c. Repeat substeps a-c to install the lower race into the

steering head.

5. Apply bearing grease to the face of each race.

Fork Stem Lower Bearing Replacement

Do not remove the steering stem lower bearing and

lower dust seal unless they are 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.

Never reinstall a lower bearing that has been removed;

it is no longer true and will damage the bearing assembly.
1. Install the steering stem bolt or nut onto the top of the
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 in Figure 66.
Slide the lower bearing and lower dust seal off the steering
stem.
3. Clean the steering stem with solvent and dry it thor-
oughly.
4. Position the new lower dust seal with the flange side
facing up.
5. Slide a

new

lower dust seal and the lower bearing onto

the steering stem until the bearing stops on the raised
shoulder.
6. Align the lower bearing with the machined shoulder on
the steering stem. Press or drive the lower bearing onto the
steering stem until it bottoms (Figure 67).

STEERING PLAY ADJUSTMENT

If aftermarket accessories have been installed on the

steering assembly, they must be removed before attempt-
ing to adjust the steering play.
1. Use a floor jack centrally located under the frame. Sup-
port the motorcycle with both the front and rear wheels
the same distance off the ground. If necessary, place a
wooden block(s) under the rear wheel until the motorcy-
cle is level on level ground.
2. On FLSTC models, remove the windshield as de-
scribed in Chapter Fourteen.
3. If any control cable is routed so that it pulls the front
end one way or the other, disconnect it.
4. Loosen the lower fork bracket pinch bolts.
5. Place a piece of masking tape transversely across the
leading edge of the front fender.

6. Swing the handlebar so that the front wheel faces
straight ahead.

7. Place a pointer on a stand so that its tip points to the
center of the fender when the wheel is facing straight
ahead.

432

CHAPTER TEN

Wood
block

Race

Head
tube

Stem nut

Steering stem

Chisel

Dust seal and bottom race

8. Lightly push the fender towards the right side until the
front end starts to turn by itself. Mark this point on the
piece of tape.

9. Repeat Step 8 for the left side.

10. Measure the distance between the two marks on the
tape. For proper bearing adjustment, the distance should
be 1-2 in. (25.4-50.8 mm). If the distance is incorrect, per-
form Step 11.

11. Adjust the steering head bearing as follows:

a. If the distance is less than 1 in. (25.4 mm), tighten

the adjusting nut, or steering stem bolt slightly.

b. If the distance is greater than 2 in. (50.8 mm) loosen

the adjusting nut, or steering stem bolt slightly.

c. Repeat Steps 8-10 until adjustment is within 1-2

inches (25.4-50.8 mm).

d. Tighten the lower fork bracket pinch bolts to 40

ft.-lb. (54 N•m).

12. Lower the motorcycle to the ground.

13. On FLSTC models, install the windshield as de-
scribed in Chapter Fourteen.

14. Connect any control cable that was disconnected.

FRONT SUSPENSION AND STEERING (TELESCOPIC FRONT FORK)

433

Bearing driver

Bearing

Table 1 FRONT SUSPENSION TORQUE SPECIFICATIONS

Item

ft.-lb.

in.-lb.

N•m

Brake hose bracket bolt

8-10

–

11-14

Front fork

Cap bolt

40-60

–

52-81

Drain screw

FXSTD

–

12-18

1.4-2.0

All models except FXSTD

–

52-78

6-9

Fork slider cap

11-15

–

15-20

Lower fork bracket pinch bolts

–

Steering stem nut

FXSTD, FXST, FSXTB

50-65

–

68-88

Steering stem bolt

FLSTC, FLSTF

–

97-124

11-14

Front fender bolts

14-18

–

19-24

Table 2 FRONT FORK OIL CAPACITY AND OIL LEVEL DIMENSION

Model

Capacity (each fork leg)

Oil level dimension

FLSTF, FLSTC, FXST

12.9 U.S. oz.

4.72 in. (119.9 mm)

FXSTB

12.0 U.S. oz.

7.28 in. (184.9 mm)

FXSTD

11.6 U.S. oz.

7.48 in. (189.9 mm)

Steering stem

CHAPTER ELEVEN

FRONT SUSPENSION AND STEERING

(SPRINGER FORK)

This chapter covers the handlebar, steering head and

front fork assemblies for the FXSTS and FLSTS. All
other models are covered in Chapter Ten.

Table 1 at the end of the chapter lists torque specifica-

tions.

WARNING

All fasteners used on the Springer front sus-
pension must be replaced with parts of the
same type. Do not use a replacement part of
lesser quality or substitute design. It may af-
fect the performance of the front suspension
or fail, leading to loss of control of the mo-
torcycle. Use the torque specifications in

Table 1

during installation to ensure proper

retention of these components.

SPRINGER SERVICE PRECAUTIONS

1. Read the applicable service procedure prior to per-
forming any service work. In some instances, it is neces-
sary to have various special tools available. Acquire all
necessary special tools prior to staring work.
2. The front wheel must be raised off the ground to per-
form some of the procedures. Make sure the motorcycle is
secure in a safe manner. See

Motorcycle Stands

in Chapter

Nine.

3. Make sure all front suspension parts and fasteners are
replaced with the same type and grade. Do not assembly
the Springer front fork with inferior parts or fasteners.

4. In most instances, there is a washer under the bolt head
or nut to prevent galling of the part being installed. This
also ensures the correct torque can be achieved when
tightening the bolt or nut. If servicing the front suspension
that had been previously been disassembled, refer to the
illustrations in this chapter to ensure that all parts and
washers are installed in the correct order.

5. The spring fork assembly is under spring pressure. If
there is any uncertainty about being able to service the
Springer fork assembly, refer this type of work to a
Harley-Davidson dealership or competent motorcycle re-
pair facility.

WARNING

All of the components that make up the
Springer front end (fork, tire and front
fender) are designed to work together to of-
fer optimum handling, steering and braking
performance. Changing or modifying any of
these components can alter the handling
and steering characteristics of the Springer
front end and may cause the loss of control.
If any accessories are going to be added,
consult with a Harley-Davidson dealership

first. Specifically, Harley-Davidson recom-
mends that the following should

not

added to or modified:

a. Do not install a tire with a higher aspect ratio. Dur-

ing hard stops, the front tire could bind against the
fender.

b. Do not lower the front fender from its stock posi-

tion. During hard stops, or when hitting big road
bumps or pot holes, the front tire could bind against
the fender.

c. Do not install a tire/wheel combination other than

that originally installed on the motorcycle. Doing so
could adversely affect the handling characteristics
of the motorcycle.

6. The rocker arm assemblies are subjected to road debris
and water. Whenever the rocker arms are removed, thor-
oughly clean the spherical bearings, pivot studs and all
pivoting parts. It may be necessary to clean the pivot studs
with crocus cloth to remove any corrosion buildup. This
type of cleaning is usually only necessary when the com-
ponents have not been routinely serviced and lubricated.
The front suspension will be stiff and will not operate cor-
rectly if these components have not been serviced cor-
rectly.

HANDLEBAR AND RISERS

Removal/Installation

Refer to Figure 1.

1. Support the motorcycle with the front wheel off the
ground. See

Motorcycle Stands

in Chapter Nine.

CAUTION

Cover the fuel tank with a heavy cloth or
plastic tarp to protect it from accidental
scratches or dents when removing the han-
dlebar.

NOTE

Before removing the handlebar, make a
drawing of the clutch and throttle cable rout-
ing from the handlebar through the frame.
This information will help when reinstalling
the handlebar and connecting the cables.

2. On the right side of the handlebar, perform the following:

a. Unscrew and remove the mirror (A, Figure 2).
b. Remove the screws securing the master cylinder (B,

Figure 2). Do not disconnect the hydraulic brake line.

c. Remove the screws securing the right side switch

assembly (C, Figure 2) and separate the housing
halves.

FRONT SUSPENSION AND STEERING (SPRINGER FORK)

435

HANDLEBAR MOUNTING

1. Bolt
2. Clamp
3. Ground spring
4. Locknut
5. Washer
6. Rubber bushing
7. Riser
8. Threaded stud
9. Upper bracket

10. Rigid fork

d. Slide the throttle housing assembly (D, Figure 2)

off the handlebar.

3. On the left side of the handlebar, perform the following:

a. Unscrew and remove the mirror (A, Figure 3).
b. Remove the screws securing the left side switch as-

sembly (B, Figure 3) and separate the housing
halves.

c. Remove the clutch lever clamp (C, Figure 3)

mounting screws and washers, and separate the
clamp halves.

4. Disconnect or remove any wiring harness clamps at
the handlebar.
5. Remove the two front handlebar clamp bolts, then the
rear clamp bolts. Remove both clamps and the handlebar.
6. Remove the ground spring (A, Figure 4) from one of
the risers.
7. To remove the riser, perform the following:

a. Loosen and remove the locknut and washer secur-

ing the riser (B, Figure 4) to the threaded stud.

b. Remove the riser from the threaded stud and if nec-

essary, remove the rubber bushings from the each
end of the riser.

8. If necessary, unscrew and remove the threaded stud
from the top of the rigid fork.
9. Inspect the handlebar as follows:

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 dam-

age. Replace the handlebar if necessary. Do not at-
tempt to repair it.

c. Thoroughly clean the upper clamps and risers of all

residue.

10. Install the handlebar by reversing these steps. Note
the following:

a. If removed, tighten the riser threaded stud to 60-65

ft.-lb. (81-88 N•m).

b. If removed, install new rubber bushings into the ris-

ers. Make sure the lip on the bottom bushing is fitted
into the recess in the bottom surface of the riser.

c. Position the risers (B, Figure 4) onto the threaded

studs so the recess will be aligned correctly to ac-
cept the handlebar.

d. Install

new

riser locknuts and tighten to 25-35 ft.-lb.

(34-47 N•m).

e. Install the ground spring (A, Figure 4) into the riser

having a ground strap attached to it.

f. After installing the handlebar, reposition the han-

dlebar while sitting on the motorcycle.

g. Tighten the handlebar clamp bolts to 144-180 in.-lb.

(16-20 N•m).

h. Adjust the mirrors.

SHOCK ABSORBER

Removal/Installation

1. Support the motorcycle with the front wheel off the
ground. See

Motorcycle Stands

in Chapter Nine.

NOTE

Cover the front fender with a heavy cloth or
towels to protect it from accidental scratches
or dents when removing the shock absorber.

436

CHAPTER ELEVEN

2. On FLSTS models, remove the horn as described in
Chapter Eight.

3. Remove the acorn nuts and washers (A, Figure 5) se-
curing the shock absorber to the upper and lower mounts.

4. Carefully lower the shock absorber (B, Figure 5) from
the upper mount and remove it. On FLSTS models, do not
scratch the passing lamp mounting bar assembly.

5. The shock absorber cannot be serviced. Check the unit
for oil leakage or loss of damping effect. Replace the
shock absorber if necessary.

6. Clean all threadlocking residue from the mounting
bolts and acorn nuts.

7. On FXSTS models, position the shock absorber with
the H-D decal faced toward the front.

CAUTION

To protect the chrome finish, place a washer
under each bolt head and between the
mounting brackets and the acorn nuts when
installing the shock mounting bolts and nuts
in Steps 7 and 8.

8. Install the shock absorber into the upper mount and
then the lower mount, then install the bolts and washers
from the left side.

9. Apply ThreeBond TB1342 threadlocking compound
to the bolt threads, then install the washers and acorn nuts
onto the bolts.

10. Secure the bolts and tighten the acorn nuts to 45-50
ft.-lb. (61-68 N•m).

WARNING

After the mounting bolts and acorn nuts are
tightened to the correct torque specification,
there should be zero clearance between the
shock absorber mounts and the shock
mounting brackets on the fork. If there is
measurable clearance between the shock
absorber and mounting brackets, first check
for loose or damaged bolts. If the bolts are
tightened correctly, check the mounting
brackets for cracks or other damage. Do not
ride the motorcycle until the shock absorber
is correctly installed and the bolts tightened
to specification.

11. On FLSTS models, install the horn as described in
Chapter Eight.

Inspection

There are no replacement parts for the shock absorber.

If any part other than the mounting hardware is defective,
replace the shock absorber.

1. Remove the shock absorber as described in this chapter.

2. Inspect the upper bushing (Figure 6) and lower bush-
ing (Figure 7) for wear and deterioration.

3. Inspect the shock absorber mounting bolt holes for
elongation.

4. Check the shock absorber (Figure 8) for fluid leakage .

FRONT SUSPENSION AND STEERING (SPRINGER FORK)

437

FORK ROCKERS

Bearing Inspection and Adjustment

Refer to Figure 9 and Figure 10.

The fork rockers pivot on the rigid fork leg via a split

ball bearing assembly. Inspect the spherical bearings in
each rocker assembly every 10,000 miles (16,000 km). At
every 50,000 miles (80,000 km) inspect the Teflon coat-
ing of the outside surface of each bearing (Figure 11). Re-

place the bearings in each rocker if the coating is worn
through to the metal at any point. If replacement is neces-
sary, replace both bearings in both rockers at the same
time.

This procedure is shown on a FXSTS model.

CAUTION

The spring fork legs must be secured to the
rigid forks during this procedure. By doing
this, the spring forks can be disconnected

438

CHAPTER ELEVEN

SPRINGER FORK ROCKERS (FXSTS)

1. Cotter pin
2. Locknut
3. Washer
4. Spring fork leg
5. Rigid fork leg
6. Bolt
7. Brake reaction link
8. Nut
9. Bearing race

10. Spherical ball bearing
11. Spherical ball bearing
12. Acorn nut
13. Bearing

14. Rocker (left side)
15. Pivot stud
16. Bearing race
17. Bearing retainer
18. Jam nut
19. Bolt
20. Washer
21. Bushing
22. Caliper mounting bracket
23. Washer
24. Wave washer
25. Spacer

from the rockers without removing the fork
assemblies from the motorcycle.

1. Support the motorcycle with the front wheel off the
ground. See

Motorcycle Stands

in Chapter Nine.

2. Remove the front caliper as described in Chapter Thir-
teen. Do not disconnect the brake line from the caliper.

3. Remove the front wheel as described in Chapter Nine.

4. On FLSTS models, remove the front fender as de-
scribed in Chapter Fourteen.

FRONT SUSPENSION AND STEERING (SPRINGER FORK)

439

SPRINGER FORK ROCKERS (FLSTS)

1. Bolt
2. Fork leg bracket
3. Washer
4. Acorn nut
5. Brake reaction link
6. Spring fork leg
7. Rigid fork leg
8. Caliper mounting bracket
9. Spherical ball bearing race

10. Spherical ball bearing
11. Pivot stud
12. Bearing retainer
13. Jam nut
14. Hex nut
15. Washer
16. Spherical ball bearing
17. Bushing
18. Teflon coated spacer
19. Pivot sleeve
20. Rocker (left side)

WARNING

If the spring fork legs are not secured to the
rigid fork legs, the spring pressure will snap
them forward with great force, which could
cause personal injury. The spring fork legs
must be secured with heavy duty cable ties
or an equivalent.

5. Use a heavy-duty cable tie, or an equivalent, and se-
cure each spring fork to the adjacent rigid fork leg (A, Fig-
ure 12). Place the cable ties close to the boss at the lower
end of the spring fork leg. Make sure the cable ties are se-
cure.

NOTE

The jam nut is located on different sides of
the fork rocker depending on model. On
FXSTS models, the jam nut (A,

Figure 13

) is

on the inboard side of the rigid fork leg. On
FLSTS models, the jam nut is on the out-
board side of the rigid fork leg.

NOTE

The jam nut requires a 1 1/2 in. box end
wrench. Do not use an open end wrench as it
will not have enough contact surface on the
jam nut that has been tightened to 95-105
ft.-lb. (129-142 N•m).

6. On the rigid fork leg, loosen but do not remove the
bearing retainer jam nut (A, Figure 13) and bearing re-
tainer (B) on the fork rocker.

7. On the spring fork, loosen the pivot studs and remove
the acorn nut (FSXST) (B, Figure 12), or hex nut
(FLSTS), and washer from each pivot stud (C, Figure
13). Leave the pivot stud in place at this time.

8. On the rigid fork, tighten the bearing retainer (Figure
14) to 25-35 in.-lbs. (3-4 N•m).

9. Secure the bearing retainer (A, Figure 15) to keep it
from rotating and tighten the jam nut to (B) 95-105 ft.-lb.
(129-142 N•m).

10. Remove the spring fork pivot stud (C, Figure 13)
loosened in Step 7. Allow the fork rocker to pivot down
away from the spring fork leg.

NOTE

While performing Step 11, check for abnor-
mal noise or movement that may indicate
damaged spherical bearing in the rigid fork
leg.

11. Attach a torque wrench onto the rigid fork pivot stud
(Figure 16) and rotate the fork rocker through its arc. The
torque reading should be 25-35 in.-lbs. (3-4 N•m).

12. If the torque reading in Step 11 is out of specification,
readjust the bearing retainer (Step 8) and repeat Step 11.
Repeat until the torque reading is correct.

13. Move the fork rocker into position and install the
spring fork pivot stud (C, Figure 13) from the inboard
side. Install the washer and nut (B, Figure 13) and tighten
the nut to 45-50 ft.-lb. (61-68 N•m).

14. Repeat Steps 6-13 for the bearing on the other fork as-
sembly.

15. Remove the heavy-duty cable ties (A, Figure 12), or
an equivalent, from the fork assemblies.

440

CHAPTER ELEVEN

16. On FLSTS models, install the front fender as de-
scribed in Chapter Fourteen.
17. Install the front wheel as described in Chapter Nine.
18. Install the front brake caliper as described in Chapter
Thirteen.

Rocker Removal

CAUTION

The spring fork legs must be secured to the
rigid forks during this procedure. By doing
this, the spring forks can be disconnected
from the rockers without removing the fork
assemblies from the motorcycle.

1. Support the motorcycle with the front wheel off the
ground. See

Motorcycle Stands

in Chapter Nine.

2. Remove the front caliper as described in Chapter Thir-
teen. Do not disconnect the brake line from the caliper.
3. Remove the front wheel as described in Chapter Nine.
4. On FLSTS models, remove the front fender as de-
scribed in Chapter Fourteen.

WARNING

5. Use a heavy-duty cable tie, or an equivalent, and secure
each spring fork to the adjacent rigid fork leg. Place the ca-
ble ties (A, Figure 17) close to the boss at the lower end of
the spring fork leg. Make sure the cable ties are secure.
6. On the spring fork, loosen the pivot stud (thick head)
and remove the acorn nut (FXSTS) (B, Figure 17), or hex
nut (FLSTS), and washer (Figure 18) from the pivot stud.
Do not remove the pivot stud at this time.

NOTE

The jam nut is located on different sides of
the fork rocker depending on model. On
FXSTS models, the jam nut (A,

Figure 13

) is

on the inboard side of the rigid fork leg. On
FLSTS models, the jam nut is on the out-
board side of the rigid fork leg.

NOTE

The jam nut requires a 1 1/2 in. box end
wrench. Do not use an open end wrench as it
will not have enough contact surface on the
jam nut and will round off the head of the
nut. The nut has been tightened to 95-105
ft.-lb. (129-142 N•m).

FRONT SUSPENSION AND STEERING (SPRINGER FORK)

441

7. Loosen and remove the bearing retainer jam nut (Fig-
ure 19).

8. Remove the pivot stud (A, Figure 20) loosened in Step 6.

9. Loosen and remove the bearing retainer (B, Figure 20).

10. On the rigid fork, loosen the pivot stud (thick head)
and remove the acorn nut (FSXST) (Figure 21), or hex
nut (FLSTS), and washer (Figure 22) from the pivot stud.

11. Remove the pivot stud (Figure 23) from the rocker
and the rigid fork leg.

12. Remove the fork rocker.

13. Remove the spherical bearings from fork rocker at
the rigid fork pivot area. Reinstall the spherical bearings
washer and nut onto the pivot stud (Figure 24) to avoid
misplacing them.

14. Repeat Steps 6-13 for the other rocker assembly.

Rocker Inspection

1. Clean all parts in solvent and dry with compressed air
(Figure 25).

2. Inspect the fork rockers (Figure 26) for cracks or dam-
age.

3. Check the rocker arm pivot studs (A, Figure 27).

442

CHAPTER ELEVEN

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Harley Davidson Softail 2000-2005. Service manual — page 25

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