Filed Under (Harley Davidson) by admin on 02-03-2011

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 (U), lockwashers (T), flat washers (S) and axle holder (R) 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) from fork tube plug. Remove quad ring seal. Save bolt 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 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. 11. Remove and save blow valve (E). 12. Remove damper tube (2). 13. Remove rebound spring (F) from damper tube. 14. Using pick tool, remove retaining clip (H) between fork slider and fork tube. 15. 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. 16. Slide fork oil seal (I), slider spacer (J) and slider bushing (K) off end of fork tube (G). 17. Remove the lower stop (L). Fork Assembly NOTE Refer to Figure 6 for the following procedure. 1. Obtain new Damper Tube (2) from kit and install rebound spring (F) over the lower end. 2. With the wear ring topside, slide new damper tube into fork tube, so that tube end drops through hole at bottom of fork tube (G). Install lower stop (L) on the lower end of damper tube. 3. Install fork slider (O or N) in fork tube holder. Slide fork tube into fork slider. 4. If necessary, obtain new slider bushing (K) (45940-84, not included). Coat slider bushing ID with clean fork oil. Slide slider bushing (K) down fork tube. 5. Slide slider spacer (J) down fork tube until it contacts slider bushing. 6. Obtain new fork oil seal (I) (45875-84A, not included). Coat fork oil seal ID with clean fork oil. With the lip garter spring side facing down (toward the fork slider), slide oil seal down fork tube until it contacts slider spacer title_tag=

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