Filed Under (Harley Davidson) by admin on 04-04-2011

REMOVAL 1. Place suitable blocking under frame to raise front wheel several inches off the floor. For best results, use a hydraulic center stand on a level surface. 2. Refer to the appropriate Service Manual and remove the front forks. 3. Move forks to bench area. Place suitable drain pan on floor beneath a vise. INSTALLATION Fork Disassembly 1. See Figure 6. Remove nuts (T), lockwashers (S), flat washers (R) and axle cap from studs at end of fork slider. 2. See Figure 1. Obtain FORK TUBE HOLDER (HD-41177) and proceed as follows: a. Clamp end of tool in vise (1) in a horizontal position with plastic knobs facing toward you. b. With the fork cap bolt topside, clamp fork tube between rubber pads (2) on inboard side of tool. Tighten knobs (3) until fork tube is securely held. NOTE Refer to Figure 6 for Steps 3-17. 3. Remove fork cap bolt (A) and spacer (O) from fork tube plug (B). Remove quad ring seal (D). Save bolt and spacer but discard quad ring seal. 4. Using wrench flat, slowly unthread fork tube plug (B) from fork tube (G). Be aware that fork tube plug is under spring -J03923 1 of 4 pressure, so have a firm grasp on plug as the last thread is turned. 5. Remove fork spring (1) from fork tube. 6. Remove fork assembly from fork tube holder. 7. Turning fork upside down, drain fork oil into drain pan. For best results, slowly pump fork tube and slider at least 10 times. 8. Install fork spring back into fork tube. 9. Place a shop rag on the floor, and turning fork assembly upside down, press end of spring against rag. While compressing spring to prevent rotation of damper tube, remove screw and washer (Q) from end of fork slider. Use air impact wrench for best results. 10. Remove and discard fork spring (1). 11. Remove dust cover (E). 12. Using pick tool, remove retaining clip (H) between fork slider and fork tube. 13. Remove fork tube (G) from fork slider. Slide fork tube gently in a slide hammer motion against the slider to remove the seals and bushing from slider. 14. Slide fork oil seal (I), slider spacer (J) and slider bushing (K) off end of fork tube (G). NOTE The lower stop (L) may come out with the damper tube or remain in the slider tube. Ensure that the lower stop is removed from the slider tube. 15. Remove the lower stop (L). 16. Remove damper tube (2) from fork tube. 17. Remove rebound spring (F) from damper tube. 18. Repeat Steps 1-17 for the opposite side fork assembly. Fork Assembly

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