Harley Davidson Softail 2000-2005. Service manual — page 24

CHAPTER TEN

FRONT SUSPENSION AND STEERING

(TELESCOPIC FORK)

This chapter covers the handlebar, steering head and

front fork assemblies for all models except the FXSTS
and FLSTS. These two Springer front fork models are
covered in Chapter Eleven.

Table 1 and Table 2 are at the end of the chapter.

HANDLEBAR

Removal/Installation

Refer to Figure 1.

1. On models so equipped, remove the windshield as de-
scribed in Chapter Fourteen.
2. Support the motorcycle with the front wheel off the
ground. See

Motorcycle Stands

in Chapter Nine.

NOTE

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.

3. 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.

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

off the handlebar.

4. 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.

5. Disconnect or remove any wiring harness clamps at
the handlebar.
6A. On FXSTD models, remove the two front handlebar
clamp bolts, then the rear clamp bolts. Remove both
clamps and the handlebar.

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6B. On all models except FXSTD, remove the two front
handlebar clamp bolts, then the rear clamp bolts (Figure
4). Remove the clamp and the handlebar.
6C. To remove the handlebar and the lower clamps as an
assembly, remove the bolt, lockwasher and washer (Fig-
ure 5) on each side securing the assembly to the upper
bracket. Remove the handlebar assembly.
7. Install the handlebar by reversing these steps. Note 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 dam-

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

c. Thoroughly clean the upper and lower clamp halves

of all residue.

d. After installing the handlebar, reposition the han-

dlebar while sitting on the motorcycle.

e. Tighten the handlebar clamp bolts securely.
f. Adjust the mirrors.

FRONT FORK

Front Fork Service

Before assuming a fork is malfunctioning, drain the

front fork oil and refill with the proper type and quantity
fork oil as described in Chapter Three. If there is still a
problem, such as poor damping, a tendency to bottom or
top out, or leakage around the oil seals, follow the service
procedures in this section.

To simplify fork service and to prevent the mixing of

parts, remove, service and install the fork legs individually.

Removal (Fork Not To Be Serviced)

1. On FLSTC models, perform the following:

a. Remove the windshield as described in Chapter

Fourteen.

b. Remove the headlight assembly as described in

Chapter Eight.

c. Remove the screws securing the front trim panel lo-

cated behind the headlight assembly.

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

Motorcycle Stands

in Chapter Nine.

3. Remove the front brake caliper as described in Chapter
Thirteen.
4. Remove the front fender and front wheel as described
in Chapter Nine.

412

CHAPTER TEN

HANDLEBAR AND RISERS

1. Screw
2. Screw
3. Upper clamp (FXSTD)
4. Handlebar (typical)
5. Upper clamp (all models except FXSTD)
6. Handlebar riser (FXSTB)
7. Handlebar riser (FLSTC and FLSTF)
8. Handlebar riser (FXST)
9. Handlebar riser (FXSTD)

10. Cup washer
11. Rubber bushing
12. Collar
13. Washer
14. Lockwasher
15. Ground cable
16. Lockwasher (right side only)
17. Bolt

5. If removing both fork tube assemblies, mark them with
an R (right side) and L (left side) so the assemblies will be
reinstalled on the correct side.

NOTE

The fork cap bolt is not under spring pres-
sure.

6. Loosen the fork cap bolt (Figure 6), then remove the
bolt, spacer and oil seal (Figure 7) from the top of the fork
tube.
7. Working at the side of the steering stem, loosen the
lower bracket pinch bolt (Figure 8).
8. Carefully slide the fork tube out of the upper fork
bracket.
9A. On FLSTC and FLSTF models, carefully slide the
fork assembly out of the lower fork bracket and the
chrome fork cover.
9B. On models other than FLSTC and FLSTF, slide the
fork assembly out of the lower fork bracket.
10. Continue to slide the fork tube out of the lower fork
bracket. It may be necessary to rotate the fork tube slightly
while pulling it down and out. Remove the fork assembly
and take it to the 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.

FRONT SUSPENSION AND STEERING (TELESCOPIC FRONT FORK)

413

11. Repeat Steps 6-10 for the other fork assembly.

Installation (Fork Was Not Serviced)

1. Position the fork assembly so that one of the flats on the
fork tube plug faces toward the inside of the motorcycle.
2A. On FLSTC and FLSTF models, carefully slide the
fork assembly up through the lower fork bracket and the
chrome fork cover.
2B. On models other than FLSTC and FLSTF, install a
fork tube through the lower fork bracket.
3. Continue to push the fork tube up through the top fork
bracket until it bottoms against the upper fork bracket.
4. Tighten the lower pinch bolt (Figure 8) finger tight at
this time.
5. Install a

new

oil seal, spacer and fork cap bolt (Figure

7). Loosen the lower fork bracket bolt and tighten the fork
cap bolt (Figure 6) to 40-60 ft.-lb. (52-81 N•m).
6. Tighten the lower bracket pinch bolt to 40 ft.-lb. (54
N•m).
7. Install the front fender and front wheel as described in
Chapter Nine.
8. Install the front brake caliper as described in Chapter
Thirteen.
9. On FLSTC and FLSTF models, perform the following:

a. Install the front trim panel located behind the head-

light assembly and tighten the screws securely.

b. Install the headlight assembly as described in Chap-

ter Eight.

c. Install the windshield as described in Chapter Four-

teen.

10. Apply the front brake and pump the front fork several
times to seat the fork tubes and front wheel.

Removal (Fork To Be Serviced)

1. On FLSTC and FLSTF models, perform the following:

a. Remove the windshield as described in Chapter

Fourteen.

b. Remove the headlight assembly as described in

Chapter Eight.

c. Remove the screws securing the front trim panel lo-

cated behind the headlight assembly.

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

Motorcycle Stands

in Chapter Nine.

3. Remove the front brake caliper as described in Chapter
Thirteen.
4. Remove the front fender and front wheel as described
in Chapter Nine.

5. If removing both fork tube assemblies, mark them with
an R (right side) and L (left side) so the assemblies will be
reinstalled on the correct side.

NOTE

The fork cap bolt is not under spring pres-
sure.

6. Loosen the fork cap bolt (Figure 6), then remove the
bolt, spacer and oil seal (Figure 7) from the top of the fork
tube.

414

CHAPTER TEN

7. Working at the side of the steering stem, loosen the
lower bracket pinch bolt (Figure 8).

8. Carefully slide the fork tube out of the upper fork
bracket.

9. Slide the fork assembly part way down and retighten
the lower bracket pinch bolt (Figure 8) securely.

10. Place a drain pan under the fork slider to catch the
fork oil.

11. Use an 8 mm Allen wrench and impact driver and
loosen the damper rod bolt at the base of the slider.

12. Remove the Allen bolt and washer and drain the fork
oil. Pump the slider several times to expel most of the fork
oil. Reinstall the Allen bolt to keep residual oil in the fork.

13. On models so equipped, slide the dust seal (A, Figure
9) up on the fork tube.

14. Remove the stopper ring from the fork slider.

15. Slide the fork slider down on the fork tube until it
stops.

NOTE

It may be necessary to slightly heat the area
on the slider around the oil seal prior to re-
moval. Use a rag soaked in hot water; do
not apply a flame directly to the fork slider.

16. There is a interference fit between the bushing in the
fork slider and the bushing on the fork tube. Remove the
fork tube from the slider, pull hard on the fork tube using
quick up and down strokes (B, Figure 9). This will with-
draw the bushing and the oil seal from the slider.
17. Remove the slider from the fork tube. Remove the oil
lock piece from the damper rod if it is still in place.

WARNING

The fork tube plug is under spring pressure,
protect yourself when removing the fork
tube plug.

18. Place a shop cloth (A, Figure 10) between the upper
fork bracket and the fork tube plug.
19. Slowly loosen the fork tube plug (B, Figure 10), then
remove it and the O-ring seal.
20. Loosen the lower bracket pinch bolt.
21A. On FLSTC and FLSTF models, carefully slide the
fork assembly out of the lower fork bracket and the
chrome fork cover.
21B. On models other than FLSTC and FLSTF, slide the
fork assembly out of the lower fork bracket (Figure 11).
22. It may be necessary to rotate the fork tube slightly
while pulling it down and out. Remove the fork assembly
and take it to the workbench for service.
23. Repeat Steps 6-22 for the other fork assembly.

Installation (Fork Was Serviced)

NOTE

Do not install the fork tube plug until the fork
assembly is installed in the lower fork
bracket. The fork spring must be compressed
in order to install the fork tube plug and it is
easier to accomplish this with the fork as-
sembly partially installed in the frame.

1. Assemble the fork(s), only up to and including the fork
spring, as described in this chapter.
2A. On FLSTC and FLSTF models, carefully slide the
fork assembly up through the lower fork bracket and the
chrome fork cover.
2B. On models other than FLSTC and FLSTF, install a fork
tube through the lower fork.
3. Continue to push the fork tube up through the lower
fork bracket until it is just above the top surface of the
lower fork bracket (Figure 11).
4. Tighten the lower bracket pinch bolt securely.
5. Install the fork tube plug as follows:

a. Install the fork tube plug on top of the fork spring

(A, Figure 12).

FRONT SUSPENSION AND STEERING (TELESCOPIC FRONT FORK)

415

b. Install an open-end wrench on the flats of the fork

tube plug (B, Figure 12).

c. Insert a socket that fits onto the top surface of the

fork tube plug (C, Figure 12) and an extension
down through the top fork bracket onto the top sur-
face of the fork tube plug.

d. Press down on the socket and extension to compress

the fork spring. Slowly thread the fork tube plug
into the fork tube being careful to not cross-thread
it. Tighten the fork tube plug securely. There is no
torque specification for this plug.

6. Loosen the lower bracket pinch bolt.

7. Position the fork assembly so one of the flats on the
fork tube plug faces toward the inside of the motorcycle.

8. Push the fork assembly up until it bottoms against the
upper fork bracket.

9. Tighten the lower bracket pinch bolt (Figure 8) finger
tight at this time.

10. Install a

new

oil seal, spacer and fork cap bolt (Figure

7). Loosen the lower fork bracket bolt and tighten the fork
cap bolt (Figure 6) to 40-60 ft.-lb. (52-81 N•m).

416

CHAPTER TEN

FRONT FORK (FXSTD)

1. Fork cap
2. Dust shield
3. Stopper ring
4. Oil seal
5. Washer
6. Slider bushing
7. Oil lock piece
8. Fork slider
9. Drain screw

10. Allen bolt and washer
11. Lower clamp (right side only)
12. Washer
13. Screw
14. Piston ring
15. Damper rod
16. Rebound spring
17. Fork tube
18. Slider bushing
19. Fork cap bolt
20. Spacer
21. Oil seal
22. Fork tube plug
23. O-ring
24. Spring

11. Tighten the lower bracket pinch bolt to 40 ft.-lb. (54
N•m).
12. Install the front fender and front wheel as described in
Chapter Nine.
13. Install the front brake caliper as described in Chapter
Thirteen.
14. On FLSTC and FLSTF models, perform the follow-
ing:

a. Install the front trim panel located behind the head-

light assembly and tighten the screws securely.

b. Install the headlight assembly as described in Chap-

ter Eight.

c. Install the windshield as described in Chapter Four-

teen.

15. Apply the front brake and pump the front fork several
times to seat the fork tubes and front wheel.

Disassembly (Without Special Tool)

Refer to Figures 13-15.

1. Remove the fork tube plug as described under.

Re-

moval (Fork To Be Serviced)

in this chapter.

2. Remove the fork spring, and drain any residual fork
oil. Dispose of the fork oil properly.

FRONT SUSPENSION AND STEERING (TELESCOPIC FRONT FORK)

417

FRONT FORK (FXST AND FXSTB)

1. Dust shield
2. Stopper ring
3. Oil seal
4. Washer
5. Slider bushing
6. Oil lock piece
7. Fork slider
8. Threaded stud
9. Drain screw and washer

10. Lower clamp (right side only)
11. Allen bolt and washer
12. Washer
13. Lockwasher
14. Nut
15. Piston ring
16. Damper rod
17. Rebound spring
18. Fork tube
19. Slider bushing
20. Fork cap bolt
21. Spacer
22. Oil seal
23. Fork tube plug
24. O-ring
25. Spring

3. Turn the fork tube upside down, and remove the
damper rod and rebound spring.

4. Slide the dust seal, oil seal, washer and fork slider
bushing off the fork tube.

5. Inspect the fork assembly as described under

Inspec-

tion (All Models)

in this chapter.

Assembly (Without Special Tool)

1. Install a

new

O-ring (Figure 16) onto the fork top plug.

418

CHAPTER TEN

FRONT FORK (FLSTC AND FLSTF)

1. Fork cap bolt
2. Spacer
3. Screw
4. Washer
5. Oil seal
6. Chrome fork cover
7. Fork tube plug
8. O-ring
9. Spring

10. Piston ring
11. Damper rod
12. Rebound spring
13. Fork tube
14. Stopper ring
15. Oil seal
16. Washer
17. Slider bushing
18. Oil lock piece
19. Oil lock piece
20. Fork slider
21. Washer
22. Drain screw
23. Threaded stud
24. Washer
25. Allen bolt
26. Lower clamp (right side only)
27. Washer
28. Lockwasher
29. Nut

2. Coat all parts with Harley-Davidson Type E Fork Oil,
or an equivalent, before assembly.

3. Install the rebound spring (Figure 17) onto the damper
rod and slide the damper rod into the fork tube until it ex-
tends out the end of the fork tube.

4. Install the oil lock piece (Figure 18) onto the end of the
damper rod.

5. Install the fork tube into the fork slider (Figure 19). Insert
a Phillips screwdriver through the opening in the bottom of
the fork tube and guide the damper rod end into the recepta-
cle in the base of the slider. Remove the screwdriver.

6. Install a new washer onto the damper rod Allen bolt
(Figure 20).

7. Apply a non-permanent threadlocking compound to
the damper rod Allen bolt threads prior to installation. In-
sert the Allen bolt and washer through the lower end of the
slider and thread it into the damper rod. Tighten the Allen
bolt securely.

8. Slide the fork slider bushing (A, Figure 21) and
washer (B) onto the fork tube.

NOTE

To protect the oil seal lips, place a thin plas-
tic bag (A,

Figure 22

) on top of the fork

tube. Before installing the seal in the follow-

FRONT SUSPENSION AND STEERING (TELESCOPIC FRONT FORK)

419

ing steps, lightly coat the bag and the seal
lips with fork oil.

9. Position the

new

oil seal with the letters facing up (B,

Figure 22) and slide it down the fork tube (C, Figure 21).

NOTE

A fork seal driver is required to install the
fork tube bushing and seal into the fork tube.
A number of different aftermarket fork seal
drivers (JIMS part No. 2046) are available.
Another method is to use a piece of pipe or a
metal collar with the correct dimensions to
slide over the fork tube and seat against the
seal. Select or fabricate a driver tool that
has sufficient weight to drive the bushing
and oil seal into the fork tube.

10. Slide the fork seal driver down the fork tube and seat
it against the oil seal (Figure 23).

11. Operate the driver and drive the fork slider bushing and
new seal into the fork tube. Continue to operate the driver
until the stopper ring groove in the tube is visible above the
fork seal (Figure 24). Remove the fork seal driver tool.

12. Install the stopper ring (Figure 25) into the slider
groove. Make sure the retaining ring seats in the groove.

13. On all models except FLSTC and FLSTF, install the
dust seal (Figure 26) and seat it into the slider.

14. Fill the fork assemblies with the correct viscosity and
quantity of fork as described under

Front Fork Oil Change

in this section.

15. Position the fork spring with the tighter wound coils
going in first and install the fork spring into the fork tube
(Figure 27).

16. Keep the fork assembly vertical and install it as de-
scribed in this chapter.

17. After installation, make sure the Allen bolt is tight
and that there is no fork oil leakage.

Disassembly (With Special Tool)

Refer to Figures 13-15.

NOTE

If the fork tube cap was not loosened and re-
moved during removal, a special fork holding
tool is required to disassemble and assemble
the fork assembly. The fork spring cannot be
compressed enough by hand to loosen and re-
move the fork tube plug. This special tool is
available from motorcycle dealerships or mo-
torcycle parts supply houses.

420

CHAPTER TEN

1. To protect the fork tube, place a steel washer (A, Fig-
ure 28) over the fork damper rod and up against the base
of the fork tube.
2. Tighten the lower bolt (B, Figure 28) so it is seated be-
low the steel washer. Do not over tighten the bolt as the
damper rod will be damaged. Make sure the tool is in-
dexed properly against the steel washer.
3. Install the special tool’s upper bolt into the hole in the
fork tube plug (A, Figure 29) following the manufac-
turer’s instructions. Make sure the tool is indexed prop-
erly in the hole in the fork tube plug.

WARNING

Be careful when removing the fork top plug
as the spring is under pressure. Protect eyes
and face accordingly.

4. Hold onto the fork tube and loosen the fork tube plug
(B, Figure 29). Slowly loosen the special tool while un-
screwing the fork tube plug.
5. When the fork tube plug is completely unscrewed from
the fork tube, loosen and remove the special tool from the
fork assembly.
6. Remove the fork tube plug and fork spring, and drain
any residual fork oil. Dispose of the fork oil properly.
7. Turn the fork tube upside down, and remove the
damper rod and rebound spring.
8. Slide the dust seal, oil seal, washer and fork slider
bushing off the fork tube.
9. Inspect the fork assembly as described under

Inspec-

tion (All Models)

in this section

Assembly (With Special Tool)

1. Install a

new

O-ring onto the fork top plug (Figure 30).

2. Coat all parts with Harley-Davidson Type E Fork Oil,
or an equivalent, before assembly.
3. Install the rebound spring (A, Figure 31) onto the
damper rod and slide the damper rod (B) into the fork tube
until it extends out the end of the fork tube.

FRONT SUSPENSION AND STEERING (TELESCOPIC FRONT FORK)

421

4. Install the oil lock piece (A, Figure 32) onto the end of
the damper rod (B).

5. Position the fork spring with the tighter wound coils
going in first (Figure 33) and install the fork spring into
the fork tube.

6. To protect the fork tube, place a steel washer (A, Fig-
ure 28) over the fork damper rod and up against the base
of the fork tube.

7. Tighten the lower bolt (B, Figure 28) so it is seated be-
low the steel washer. Do not over tighten the bolt as the
damper rod will be damaged. Make sure the tool is in-
dexed properly against the steel washer.

8. Position the fork tube plug onto the top of the fork
spring.

9. Install the special tool’s upper bolt into the hole in the
fork tube plug (A, Figure 34) following the manufac-
turer’s instructions. Make sure the tool is indexed prop-
erly in the hole in the fork tube plug.

CAUTION

While tightening the special tool, do not
jamb the fork tube plug into the threaded
portion of the fork tube. This will damage
the threads on both parts.

10. Hold onto the fork tube plug and slowly tighten the
special tool while guiding the fork tube plug into the top
of the fork tube (B, Figure 34).

11. Place a wrench on the fork tube plug (B, Figure 29)
and screw the fork tube plug into the fork tube while tight-
ening the special tool. Once the fork tube plug has started
to thread into the fork tube, loosen the special tool and re-
move it from the fork assembly.

12. Place the slider in a vise with soft jaws and tighten the
fork top plug (Figure 35) securely.

13. Push the fork slider and damper rod (Figure 36) into
the fork slider. Insert a Phillips screwdriver through the
opening in the bottom of the fork tube and guide the

422

CHAPTER TEN

damper rod end into the receptacle in the base of the slider.
Remove the screwdriver.
14. Install a new washer onto the damper rod Allen bolt.
15. Apply a non-permanent threadlocking compound to
the damper rod Allen bolt threads prior to installation. In-
sert the Allen bolt (Figure 37) and washer through the
lower end of the slider and thread it into the damper rod.
Tighten the bolt securely.

NOTE

To protect the oil seal lips, place a thin plas-
tic bag on top of the fork tube. Before in-
stalling the seal in the following steps,
lightly coat the bag and the seal lips with
fork oil.

16. Slide the fork slider bushing (A, Figure 38), washer
(B) and oil seal (C) (with the letters facing up) down into
the fork tube receptacle (Figure 39).

NOTE

17. Slide the fork seal driver down the fork tube and seat
it against the oil seal (Figure 40).
18. Operate the driver and drive the fork slider bushing
and new seal into the fork tube. Continue to operate the
driver until the stopper ring groove in the tube is visible
above the fork seal. Remove the fork seal driver tool.
19. Install the stopper ring (Figure 41) into the slider
groove. Make sure the retaining ring seats in the groove
(Figure 42).

FRONT SUSPENSION AND STEERING (TELESCOPIC FRONT FORK)

423

20. Fill the fork assemblies with the correct viscosity and
quantity of fork as described under

Front Fork Oil

Change

in this section

21. Install the fork tube as described in this chapter.

Inspection (All Models)

Replace 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 for bending, nicks, rust or other
damage. Place the fork tube on a set of V-blocks and
check runout with a dial indicator. If the special tools are
not available, roll the fork tube on a large plate glass or an-
other flat surface. Harley-Davidson does not provide ser-
vice specifications for runout.

3. Check the internal threads in the top of the fork tube
(Figure 43) for stripping, cross-threading or sealer resi-
due. Use a tap to true the threads and to remove sealer de-
posits.

4. Check the fork tube plug O-ring (A, Figure 44) for
hardness or deterioration. Replace if necessary.

5. Check the external threads on the fork tube plug (B,
Figure 44) for stripping, cross-threading or sealer resi-
due. Use a die to true the threads and to remove sealer de-
posits.

6. Make sure the oil passage hole in the fork tube (Figure
45) is open. If it is clogged, flush it with solvent and dry it
with compressed air.

7. Check the fork cap bolt O-ring (A, Figure 46) for hard-
ness or deterioration. Replace if necessary.

8. Check the external threads on the fork cap (B, Figure
46) for stripping, cross-threading or sealer residue. Use a
die to true the threads and to remove sealer deposits.

9. Check the slider (Figure 47) for dents or other exterior
damage. Check the retaining ring groove (Figure 48) in
the top of the slider for cracks or other damage.

424

CHAPTER TEN

10. Check the front caliper mounting bosses for cracks or
damage.

11. Check the threaded studs (A, Figure 49) on the base
of the slider for thread damage. Repair if necessary.

12. Check the drain screw (B, Figure 49) and washer for
damage.

13. Check the slider (A, Figure 50) and fork tube bush-
ings (B) for excessive wear, cracks or damage.

14. Remove the fork tube bushing as follows:

a. Expand the bushing slit (Figure 51) with a screw-

driver and slide the bushing off the fork tube.

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.

15. Check the damper rod piston ring (A, Figure 52) for
excessive wear, cracks or other damage. If necessary, re-
place both rings as a set.

16. Check the damper rod (B, Figure 52) for straightness
with a set of V-blocks and a dial indicator (Figure 53), or
by rolling it on a piece of plate glass. Specifications for
runout are not available. If the damper rod is not straight,
replace it.

FRONT SUSPENSION AND STEERING (TELESCOPIC FRONT FORK)

425

17. Make sure the oil passage hole in the damper rod (C,
Figure 52) is open. If it is clogged, flush it with solvent
and dry it with compressed air.
18. Check the internal threads in the bottom of the
damper rod for stripping, cross-threading or sealer resi-
due. Use a tap to true the threads and to remove sealer de-
posits.
19. Check the damper rod rebound spring and the fork
spring for wear or damage. Service limit specifications for
spring free length are not available. If necessary, replace
both fork springs as a set.
20. Replace the oil seal whenever it is removed. Always
replace both oil seals as a set.

Front Fork Oil Change

NOTE

Always adjust fork oil by measuring the fork
oil level. Do not rely on the fork oil capacity.
Inaccurate setting will result.

1. Secure the fork vertically in a vise with soft jaws.
2. Push the fork tube down into the slider until the tube
bottoms.
3. Refer to Table 2 and add the recommended amount of
fork oil into the fork assembly.
4. Slowly raise and lower the fork tube several times to
distribute the oil.
5. After the fork oil, settles fully compress the fork tube.
6. Use an accurate ruler or the Motion Pro oil gauge (part
No. 08-0121) (Figure 54), or an equivalent, to achieve the
correct oil level listed in Table 2.
7. Allow the oil to settle completely and recheck the oil
level measurement. Adjust the oil level if necessary.
8. Remove the special tool.
9. Fully extend the fork tube and install the fork as de-
scribed in this chapter.

STEERING HEAD AND STEM

Removal (FLSTC and FLSTF Models)

Refer to Figure 55.

1. On FLSTC models, remove the windshield as de-
scribed in Chapter Fourteen.
2. Remove the fuel tank as described in Chapter Seven.
3. Remove the front fender and front wheel as described
in Chapter Nine.
4. Remove both front fork legs as described in this chap-
ter.
5. Remove the handlebar as described in this chapter.

6. Remove the headlight and headlight bracket as de-
scribed in Chapter Eight.

7. Remove the screws and nuts securing the front and
back trim panels to the upper and lower brackets. Remove
all three panels.

8. Remove the screws and lockwashers securing the fork
tube covers and remove both covers.

9. Remove the bolt securing the front brake hose to the
bottom of the lower fork bracket. Do not disconnect any
brake hose connections.

10. Remove the steering stem cap.

11. Loosen the pinch bolt on the upper bracket.

CAUTION

Hold or secure the steering stem to keep it
from falling after removal of the fork stem
bolt and washer in Step 12.

12. Loosen and remove the fork stem bolt and washer.

13. Remove the upper fork bracket, then slide the steer-
ing stem/lower bracket out of the steering head.

426

CHAPTER TEN

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Harley Davidson Softail 2000-2005. Service manual — page 24

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