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Harley Davidson 1999-2005 Harley Dyna Models. Repair Manual - page 21

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400

CHAPTER NINE

7. Press the upper bead into the rim opposite the

valve stem (Figure 61). Pry the bead into the rim on

61

both sides of the initial point with both hands and

work around the rim to the valve stem (Figure 62).

If the tire wants to pull up on one side, either use a

tire iron or one knee to hold the tire in place. The

last few inches are usually the toughest to install.

Continue to push the tire into the rim by hand.

Re-lubricate the bead if necessary. If the tire bead

wants to pull out from under the rim use both knees

to hold the tire in place. If necessary, use a tire iron

for the last few inches.

8. Bounce the wheel several times, rotating it each

time. This will force the tire bead against the rim

62

flanges. After the tire beads are in contact with the

rim, inflate the tire to seat the beads.

9. Place an inflatable band around the circumference

of the tire. Slowly inflate the band until the tire beads

are pressed against the rim. Inflate the tire enough to

make it seat, deflate the band and remove it.

WARNING

In the next step, never exceed 40 psi

(276 kPa) inflation pressure as the tire

could burst, causing severe injury.

Never stand directly over a tire while

inflating it.

63

10. After inflating the tire, check to see that the

beads are fully seated and that the rim lines are the

same distance from the rim all the way around the

tire. If the beads will not seat, deflate the tire and lu-

bricate the rim and beads with soapy water.

11. Re-inflate the tire to the pressure listed in Table

4. Install the valve stem cap.

12. Balance the wheel as described in this chapter.

13A. Install the front wheel as described in this chapter.

13B. Install the rear wheel as described in this chapter.

TIRE REPAIRS

Tubeless tires have TUBELESS molded into the

sidewall and the rims have SUITABLE FOR

NOTE

TUBELESS TIRES or equivalent stamped or cast

Changing or patching on the road is

on them.

very difficult. A can of pressurized tire

If the tire is punctured, it must be removed from

inflator and sealer may inflate the tire

the rim to inspect the inside of the tire and to apply a

and seal the hole, although this is only

combination plug/patch from inside the tire (Figure

a temporary fix.

63). Never attempt to repair a tubeless motorcycle

tire using a plug or cord patch applied from outside

WARNING

Do not install an inner tube inside a

the tire.

tubeless tire. The tube will cause an

After repairing a tubeless tire, don’t exceed 50

abnormal heat buildup in the tire.

mph (80 km/h) for the first 24 hours.

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WHEELS, HUBS AND TIRES

401

Repair

64

Do not rely on a plug or cord patch applied from

outside the tire. Use a combination plug/patch ap-

plied from inside the tire (Figure 63).

1. Remove the tire from the wheel rim as described

in this chapter.

2. Inspect the rim inner flange. Smooth any

scratches on the sealing surface with emery cloth. If

a scratch is deeper than 0.5 mm (0.020 in.), the

Gauge

wheel should be replaced.

3. Inspect the tire inside and out. Replace a tire if

any of the following is found:

a. A puncture larger than 3 mm (1/8 in) diameter.

b. A punctured or damaged side wall.

c. More than 2 punctures in the tire.

4. Apply the plug/patch following the manufac-

turer’s instructions with the patch kit.

Tire Runout

Tire lateral

runout

Check the tires for excessive lateral and radial

9

runout after a wheel has been mounted or if the mo-

torcycle developed a wobble that cannot be traced

to another component. Mount the wheels on their

axles when making the following checks.

1. Lateral runout: This procedure will check the tire

65

for excessive side-to-side play. Perform the following:

a. Position a fixed pointer next to the tire sidewall

as shown in Figure 64. Position the pointer tip

so that it is not directly in line with the molded

tire logo or any other raised surface.

b. Rotate the tire and measure lateral runout.

c. The lateral runout must not exceed 0.080 in.

(2.03 mm). If runout is excessive, remove the

tire from the wheel and recheck the wheel’s

lateral runout as described in this chapter. If the

runout is excessive, the wheel must be trued

(laced wheels) or replaced (alloy wheels). If

wheel runout is correct, the tire runout is ex-

cessive and the tire must be replaced.

2. Radial runout: This procedure will check the tire

for excessive up-and-down play. Perform the follow-

ing:

a. Position a fixed pointer at the center bottom

Tire radial

of the tire tread as shown in Figure 65.

runout

Gauge

b. Rotate the tire and measure the amount of ra-

dial runout.

c. The radial runout must not exceed 0.090 in.

(2.29 mm). If runout is excessive, remove the

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402

CHAPTER NINE

tire from the wheel and recheck the wheel’s

radial runout as described in this chapter. If

66

the runout is excessive, true or replace the

wheel. If wheel runout is correct, the tire run-

out is excessive and the tire must be replaced.

VEHICLE ALIGNMENT

This procedure checks the alignment of the rear

axle with the swing arm pivot shaft. It also checks

the engine stabilizer adjustment that aligns the en-

gine in the frame. These checks determine the con-

dition and alignment of the components that hold

the motorcycle together: steering stem, front axle,

67

engine, swing arm pivot shaft and rear axle. If any

of these items are out of alignment, the motorcycle

will not handle properly. Bad handling will increase

the motorcycle’s vibration level while reducing its

overall performance and driveability.

Preliminary Inspection

Before checking vehicle alignment, make the fol-

lowing checks to spot problems caused from normal

wear. Adjust, repair or replace any component as re-

quired.

68

1. The engine stabilizer (Figure 66), mounted be-

tween the cylinder heads and upper frame tube,

Grommet

aligns the engine in the frame. Check the engine sta-

bilizer every 10,000 miles (16,000 km) for loose or

damaged parts. To service or replace the engine sta-

1-1/4 in.

bilizer, refer to Chapter Four. To adjust the engine

(32 mm)

10 in.

stabilizer, perform the Alignment procedure in this

(254 mm)

section.

2. Check the steering head bearing adjustment as

described under Steering Play Adjustment in Chap-

ter Ten.

3. Check the runout of each wheel as described in

this chapter.

2. A rear axle alignment tool is made of 1/8

in. (3.2

mm) welding rod 11 in. (280 mm) long, as shown in

Figure 68. The grommets can be purchased from

Special Tools

electronic supply and hardware stores. To use this tool

accurately, the grommet must be a snug fit on the tool.

The following tools are required to check vehicle

alignment:

1. An inclinometer (Figure 67) checks the vertical

Alignment

position (angle) of the brake discs when checking

engine alignment. This tool, which has a magnetic

Each alignment step (check and adjustment) af-

base and a 360-degree dial, can be purchased from

fects the next one. Work carefully and accurately

most tool and hardware stores.

when performing the following steps.

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WHEELS, HUBS AND TIRES

403

Axle alignment is correct if the two measurements

69

are within 0.032 in. (0.8 mm) of each other.

6. If the alignment is incorrect, perform the Final

Drive Belt Adjustment procedure in Chapter Three.

When the drive belt adjustment is correct, continue

with Step 7.

NOTE

The following steps must be performed

with the rear wheel off the ground.

7. Remove the bolt (Figure 70) securing the stabi-

lizer link to the engine mounting bracket. Do not re-

move the bolt securing the stabilizer link to the

frame.

70

8. Place the inclinometer on the front brake disc.

Position the front wheel so that the brake disc is ver-

Locknut

Front

tical (90°). This position must be maintained when

performing Steps 9 and 10.

9. Align the stabilizer link hole with the engine

mounting bracket and install the stabilizer link bolt

(Figure 70). Do not force the bolt into position.

Note the following:

Adjust nut

9

a. If the holes do not align, adjust the stabilizer,

starting with Step 10.

Stabilizer link

b. If the holes align, go to Step 14.

10. Loosen the stabilizer locknut. Then adjust the

stabilizer link until the bolt can be installed without

Engine mounting bracket

moving the engine. Tighten the locknut when the

adjustment is correct.

11. Now put the inclinometer on the rear brake disc

1.

Perform all of the checks listed under Prelimi-

and compare its position with the front brake disc. If

nary Inspection in this section. When all of the

the readings are not within 1° of each other, con-

checks are within the specifications, continue with

tinue with Step 12.

Step 2. If the motorcycle has been involved in a

12. Readjust the stabilizer link (Step 10) until the

crash, refer frame alignment to a Harley-Davidson

rear brake disc is within 1° of the front brake disc.

dealership or motorcycle frame alignment special-

Note the following:

ist.

a. If the adjustment cannot bring the brake discs

2. The exhaust system must be installed on the mo-

within 1° of each other, inspect the swing

torcycle when performing the following steps.

arm, frame, steering head and front forks for

damage. If necessary, take the motorcycle to a

3. Support the motorcycle with the rear wheel off

Harley-Davidson dealership for further in-

the ground.

spection.

4. Insert the alignment tool (Figure 68) into one of

b. If the adjustment can bring the brake disc an-

the swing arm index holes. Then hold it parallel

gle to within 1°, but it takes more than five

with the rear axle and slide the grommet along the

turns of the stabilizer link to do so, perform

tool until it is centered with the axle (Figure 69).

the chassis inspections described in substep a.

5. Remove the alignment tool without disturbing

If a problem can not be found with a chassis

the position of the grommet and insert the tool into

component, go to Step 13.

the opposite side of the swing arm. Compare the

c. If the adjustment cannot bring the brake discs

axle center point with the position of the grommet.

within 1° and it takes less than five turns of

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FRONT SUSPENSION AND STEERING

407

1

HANDLEBAR

3

4

10

b. Unscrew and remove the mirror (B, Figure

1. Allen bolt

2. Washer

2).

3. Holder

c. Remove the screws securing the master cylin-

4. Handlebar

der (C, Figure 2). Do not disconnect the hy-

5. Lower clamp

draulic brake line.

6. Cup washer

7. Rubber bushing

d. Loosen the throttle housing

(D, Figure 2)

8. Collar

screws and slide the assembly off the handlebar.

9. Washer

3. On the left side of the handlebar, perform the fol-

10. Bolt

lowing:

11. Washer

12. Ground cable

a. Remove the front turn signal (A, Figure 3)

from the master cylinder.

b. Unscrew and remove the mirror (B, Figure

3).

c. Remove the screws securing the left side

2

switch assembly together (C, Figure 3) and

separate the housing halves.

d. Remove the clutch lever clamp (D, Figure 3)

mounting screws and separate the clamp

halves.

4. Disconnect or remove any wiring harness

clamps at the handlebar.

5A. On FXD, FXDS-CON, FXDX and FXDXT

models, remove the two front handlebar clamp bolts

(A, Figure 4) and washers. Then set the instrument

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408

CHAPTER TEN

housing forward (B) so it does not scratch the han-

dlebar clamp.

5

5B. On all other models, remove the two front han-

dlebar clamp bolts (A, Figure 4) and washers.

6. Remove the two rear clamp bolts (C, Figure 4),

then remove the holder (D) and handlebar (E).

7. Install the handlebar by reversing these steps

while noting 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 damage. Replace the handlebar if nec-

essary. Do not attempt to repair it.

6

FORK INSTALLATION

c. Thoroughly clean the clamp halves of all resi-

due.

d. After installing the handlebar, reposition the

handlebar while sitting on the motorcycle.

0.42-0.50 in.

Cap bolt

e. Tighten the handlebar clamp bolts securely.

(10.7-12.7 mm)

f. Adjust the mirrors.

FRONT FORK

(FXD, FXDL, FXDS-CON, FXDWG,

FXDP AND 1999 FXDX)

Bracket

Fork tube

Front Fork Service

Before assuming that a fork is internally malfunc-

tioning, drain the front fork oil and refill with the

proper type and quantity of fork oil as described in

5.

On FXDWG models, remove the fork tube cap,

Chapter Three. If there is still a problem, such as

spacer and oil seal from the top of one fork tube.

poor damping or a tendency to bottom or top out,

6. Loosen the upper fork bracket pinch bolt (A,

follow the service procedures in this section.

Figure 5).

To simplify fork service and to prevent the mix-

7A. On FXDWG models, if the forks are going to be

ing of parts, remove, service and install the fork legs

disassembled, loosen the fork tube plug.

individually.

7B. On all models other than FXDWG models, if

the forks are going to be disassembled, loosen the

fork cap (B, Figure 5).

Removal

8. Loosen the lower fork bracket pinch bolt and

slide the fork tube out of the fork brackets. It may be

1. Support the motorcycle with the front wheel off

necessary to rotate the fork tube slightly while pull-

the ground. See Motorcycle Stands in Chapter Nine.

ing it down and out. Remove the fork assembly and

2. Remove the front fender and front wheel as de-

take it to the workbench for service. If the fork is not

scribed in Chapter Nine.

going to be serviced, wrap it in a bath towel or blan-

3. If both fork tube assemblies are going to be re-

ket to protect the surface from damage.

moved, mark them with an R (right side) and L (left

side) so the assemblies will be reinstalled on the

NOTE

correct side.

Identify the fork tubes so they will be

4. On FXDX-CON models, remove the windshield

installed on the correct side.

and its mounting clamps as described in Chapter

Thirteen.

9. Repeat for the other fork assembly.

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FRONT SUSPENSION AND STEERING

409

Installation

7

FRONT FORK (FXD, FXDL,

FXDS-CON, FXDP,

1. Clean off any corrosion or dirt on the upper and

1999 FXDX)

lower fork bracket receptacles.

2A. On FXD, FXDL, FXDS-CON and 1999 FXDX

models, install each fork tube so that the tube ex-

tends 0.42-0.50 in. (10.7-12.7 mm) above the upper

fork bracket as shown in Figure 6.

2B. On FXDWG models, perform the following:

a. Install a fork tube through the fork brackets

and tighten the lower pinch bolt.

b. Position the fork tube so that one flat on the

fork tube plug faces toward the steering stem.

Hold the fork in this position and install the

new oil seal, washer and the fork tube top cap.

Repeat for the other fork tube.

c. Position the fork tube so it is flush with the

top surface of the upper fork bracket.

3. Tighten the lower fork bracket pinch bolt to the

specification in Table 1.

4. If loose, tighten the fork cap (B, Figure 5) se-

curely.

5. Tighten the upper fork bracket pinch bolt (A,

Figure 5) to the specification in Table 1.

6. On FXDWG models, tighten the fork tube cap

10

securely.

7. Install the front fender and front wheel as de-

scribed in Chapter Nine.

8. Apply the front brake and pump the front fork

several times to seat the fork and front wheel.

Disassembly

Refer to Figure 7 or Figure 8.

1. Clamp the fork slider’s front axle boss in a vise

with soft jaws. Do not clamp the slider at any point

above the fork axle boss in a vise.

1.

Center plug

13.

Retainer ring

NOTE

2.

Top cap

14.

Oil seal

Loosen the bottom Allen bolt before

3.

O-ring

15.

Oil seal spacer

removing the fork cap and spring.

4.

Spring

16.

Slider bushing

Leaving the cap on provides spring

5.

Piston ring

17.

Oil lock piece

tension against the damper rod. This

6. Piston ring

18.

Slider

prevents the damper rod from turning

7. Damper rod

19.

Drain screw

8. Rebound spring

20.

Clap bolt

when loosening the Allen bolt.

9. Fork tube

21.

Nut

10. Fork tube

22.

Lockwasher

2. Loosen the Allen bolt from the bottom of the

bushing

23.

Washer

slider. Do not remove it at this time, as fork oil will

11. Dust seal cover

24.

Washer

drain out.

12. Dust seal

25.

Allen bolt

3A. On all models except FXDWG, if the fork top

cap was not loosened during removal, hold the fork

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410

CHAPTER TEN

tube in a vise with soft jaws and loosen the fork top

cap.

8

FRONT FORK (FXDWG)

3B. On FXDWG models, if the fork top plug was

not loosened during removal, hold the fork tube in a

vise with soft jaws and loosen the fork top plug.

WARNING

Be careful when removing the top cap,

or top plug, as the spring is under

pressure. Protect eyes and face ac-

cordingly.

4. With the fork assembly vertical, remove the fork

top cap, or top plug, from the top of the fork tube.

5. Remove the spring from the fork tube.

6. Remove the fork tube from the vise and pour the

oil into a drain pan. Pump the fork several times by

hand to expel most of the remaining oil.

7A. On all models except FXDWG, remove the dust

seal cover from the slider. Insert a small flat-tipped

screwdriver under the dust seal (Figure 9) and care-

fully pry the dust seal out of the slider and remove it.

7B. On FXDWG models, insert a small flat-tipped

screwdriver under the dust cover and carefully pry

the dust cover out of the slider and remove it.

8. Pry the retaining ring (Figure 10) out of the

groove in the slider and remove it.

9. Remove the Allen bolt and washer (Figure 11)

at the bottom of the slider.

10. There is an interference fit between the bushing

in the fork slider and the bushing on the fork tube. In

order to remove the fork tube from the slider, pull

hard on the fork tube using quick in-and-out strokes

(Figure 12). Doing so will withdraw the bushing

and the oil seal from the slider.

NOTE

1.

Top cap

15.

Oil seal spacer

It may be necessary to slightly heat

2.

Spacer

16.

Slider bushing

the area on the slider around the oil

3.

Oil seal

17.

Oil lock piece

seal prior to removal. Use a rag

4.

Fork tube plug

18.

Slider

soaked in hot water; do not apply a

5.

O-ring

19.

Washer (damper

flame directly to the fork slider.

6.

Spring

rod)

7.

Piston ring

20.

Allen bolt

11. Withdraw the fork tube from the slider.

8.

Damper rod

(damper rod)

9.

Rebound spring

21.

Axle cap

10.

Fork tube

22.

Stud

NOTE

11.

Fork tube

23.

Drain screw

Do not remove the fork tube bushing

bushing

24.

Washer

unless it is going to be replaced. In-

12.

Dust seal cover

25.

Washer

spect it as described in this chapter.

13.

Retainer ring

26.

Lockwasher

14.

Oil seal

27.

Nut

12. Remove the oil lock piece (Figure 13) from the

damper rod.

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FRONT SUSPENSION AND STEERING

411

9

13

10

14

10

11

15

13. Remove the damper rod and rebound spring

12

(Figure 14) from the fork tube.

Inspection

Replace any 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 (A, Figure 15) for bending,

nicks, rust or other damage. Place the fork tube on a

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412

CHAPTER TEN

16

17

set of V-blocks and check runout with a dial indica-

tor. If the special tools are not available, roll the fork

18

tube on a large plate glass or other flat surface.

Specifications for runout are not available.

3. Check the slider (B, Figure 15) for dents or other

exterior damage. Check the retaining ring groove

(Figure 16) in the top of the slider for cracks or

other damage.

4. Check the slider and fork tube bushings for ex-

cessive wear, cracks or damage.

5. To remove the fork tube bushing, perform the

following:

a. Expand the bushing slit (Figure 17) with a

screwdriver and then slide the bushing off the

fork tube.

19

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.

6. Check the damper rod piston rings (Figure 18)

for excessive wear, cracks or other damage. If nec-

essary, replace both rings as a set.

7. Check the damper rod for straightness with a set

of V-blocks and a dial indicator (Figure 19) or by

rolling it on a piece of plate glass. Service limit

specifications for runout are not available. If the

damper rod is not straight, replace it.

20

8. Make sure the oil passage holes in the damper

rod (Figure 20) are open. If clogged, flush with sol-

vent and dry with compressed air.

9. Check the threads in the bottom of the damper

rod for stripping, cross-threading or sealer residue.

Use a tap to true up the threads and to remove sealer

deposits.

10. Check the damper rod rebound spring and the

fork spring for wear or damage. Service limit speci-

fications for spring free length are not available.

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FRONT SUSPENSION AND STEERING

413

21

25

11. Replace the oil seals (A, Figure 21) whenever

22

they are removed. Always replace both oil seals as a

set.

12. Inspect the dust seals (B, Figure 21) or dust

covers, for cracks, deterioration or other damage. A

damaged dust seal, or dust cover, will allow dirt to

pass through and damage the oil seal.

13. Replace the fork top cap, fork tube plug, or

O-ring if leaking or if wear or damage is apparent.

Assembly

10

1. Coat all parts with Harley-Davidson Type E

Fork Oil, or an equivalent, fork oil before assembly.

23

2. Install the rebound spring onto the damper rod

(Figure 22) and slide the damper rod into the fork

tube until it extends out the end of the fork tube.

3. Install the oil lock piece (Figure 23) onto the end

of the damper rod.

4. Temporarily install the fork spring (A, Figure

24) into the fork tube so that the tapered side of the

spring faces down toward the damper rod.

5A. On all models except FXDWG, install the fork

top cap (B, Figure 24), screw it into place to hold

the damper rod in place.

5B. On FXDWG models, install the fork top plug

and screw it into place to hold the damper rod in

24

place.

6. Push the fork slider and damper rod through the

opening in the bottom of the fork tube.

7. Make sure the oil lock piece is mounted on the

end of the damper rod. Install the fork tube into the

slider (Figure 25) until it bottoms.

8. Install a new washer onto the damper rod Allen

bolt.

9. Apply a non-permanent threadlocking com-

pound to the damper rod Allen bolt threads prior to

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414

CHAPTER TEN

installation. Insert the Allen bolt

(Figure

11)

through the lower end of the slider and thread it into

26

the damper rod. Tighten the bolt securely.

NOTE

To protect the oil and dust seal lips,

place a thin plastic bag on top of the

fork tube. Before installing the seals

in the following steps, lightly coat the

bag and the seal lips with fork oil.

10. Slide the fork slider bushing (A, Figure 26), oil

seal spacer (B) and oil seal (C) (with the letters fac-

ing up) down into the fork tube receptacle.

27

NOTE

A 39 mm fork seal driver is required to

install the fork tube bushing and seal

into the fork tube. A number of differ-

ent aftermarket fork seal drivers are

available that can be used for this

purpose. Another method is to use a

piece of pipe or metal collar with cor-

rect dimensions to slide over the fork

tube and seat against the seal. When

selecting or fabricating a driver tool,

it must have sufficient weight to drive

the bushing and oil seal into the fork

tube. A fork seal and cap installer

28

(JIMS part No. 2046) is used in this

procedure.

11. Slide the fork seal driver down the fork tube

and seat it against the seal (Figure 27).

12. Operate the driver and drive the fork slider

bushing and new seal into the fork tube. Continue

until the stopper ring groove in the tube is visible

above the fork seal. Remove the fork seal driver

tool.

13. Install the retaining ring (Figure 28) into the

slider groove. Make sure the retaining ring seats in

17. Fill the fork tube with the correct quantity of

the groove.

Harley-Davidson Type E Fork Oil listed in Table 2.

14A. On all models except FXDWG, install the dust

18. The fork spring is tapered at one end. Install the

seal (Figure 29) and seat it into the slider, then in-

spring (A, Figure 24) with the tapered end facing

stall the dust seal cover.

down toward the damper rod.

14B. On FXDWG models, install the dust cover and

seat it into the slider.

19A. On all models except FXDWG, perform the

following:

15A. On all models except FXDWG, unscrew and

remove the fork top cap.

a. Apply fork oil to the fork top cap O-ring.

15B. On FXDWG models, unscrew and remove the

b. Align the fork top cap with the spring and

fork top plug.

push down on the fork top cap to compress

16. Remove the fork spring.

the spring.

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FRONT SUSPENSION AND STEERING

415

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

29

FRONT FORK

(FXDXT, 2000-ON FXDX)

Front Fork Service

Before assuming that a fork is internally malfunc-

tioning, drain the front fork oil and refill with the

proper type and quantity of fork oil as described in

this chapter. If there is still a problem, such as poor

damping, or a tendency to bottom or top out, follow

the service procedures in this section.

To simplify fork service and to prevent the mix-

30

ing of parts, remove, service and install fork legs in-

dividually.

Removal/Installation

(Fork Not To Be Serviced)

1. Remove the front fender and front wheel (A,

Figure 30) as described in Chapter Eleven.

2. Loosen the upper and lower bracket pinch bolts

(B, Figure 30).

3. If both fork tube assemblies are going to be re-

10

moved, mark them with an R (right side) and L (left

31

side) so the assemblies will be reinstalled on the

correct side.

4. Carefully lower the fork assembly out of the up-

per and lower fork brackets. It may be necessary to

rotate the fork tube slightly while pulling it down

and out. Remove the fork assembly and take it to a

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.

5. Slowly install the fork tube into the lower fork

bracket then the upper fork bracket.

NOTE

c. Start

the

cap slowly,

making sure it is

not

There is no specification for the loca-

cross-threaded. Tighten it finger-tight.

tion of the top of the fork tube. How-

19B. On FXDWG models, perform the following:

ever, as a guideline, set the fork tube

a. Apply fork oil to the fork top plug O-ring.

approximately 0.08 in (2.0 mm) above

the top surface of the upper fork

b. Align the fork top plug with the spring and

bracket (Figure 31).

push down on the fork top plug to compress

the spring.

6. With the fork assembly in position, tighten the

c. Start the plug slowly, making sure it is not

upper and lower bracket pinch bolts to the torque

cross-threaded. Tighten it finger-tight.

specification listed in Table 2.

20. Place the slider in a vise with soft jaws and

7. Install the front wheel and front fender as de-

tighten the fork top cap, or fork top plug, securely.

scribed in Chapter Nine.

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416

CHAPTER TEN

32

33

Removal/Installation

(Fork To Be Serviced)

34

1. Remove the front fender and front wheel as de-

scribed in Chapter Eleven.

2. If both fork tube assemblies are going to be re-

moved, mark them with an R (right side) and L (left

side) so the assemblies will be reinstalled on the

correct side.

3. Place a drain pan under the fork slider.

4. Use an 8 mm Allen wrench and impact driver

and loosen the damper rod cartridge 8 mm Allen

bolt at the base of the slider.

5. Remove the Allen bolt (Figure 32) and drain the

35

fork oil. Pump the slider several times to expel most

of the fork oil. Reinstall the Allen bolt to keep resid-

ual oil in the fork.

6. Carefully pry the cover (A, Figure 33) from the

fork slider.

7. Remove the dust seal and stopper ring (B, Fig-

ure 33) from the fork slider.

8. Lower the fork slider on the fork tube.

NOTE

It may be necessary to slightly heat

the area on the slider around the oil

seal prior to removal. Use a rag

soaked in hot water; do not apply a

36

flame directly to the fork slider.

9. There is an interference fit between the bushing

in the fork slider and the bushing on the fork tube. In

order to remove the fork tube from the slider, pull

hard on the fork tube using quick in-and-out strokes

(Figure 34). Doing so will withdraw the bushing

and the oil seal from the slider.

10. Loosen the upper and lower bracket pinch bolts

(Figure 35).

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FRONT SUSPENSION AND STEERING

417

11. Carefully lower the fork assembly out of the

37

FRONT FORK

upper bracket. It may be necessary to rotate the fork

(FXDX 2000-ON, FXDXT)

tube slightly while pulling it down.

12. Lower the fork tube between the upper and the

lower brackets and tighten the lower bracket pinch

bolt.

13. Loosen the fork cap bolt (Figure 36).

14. Loosen the lower bracket pinch bolt and re-

move the fork from the lower bracket.

15. Service the fork assembly as described in this

chapter.

16. Slowly install the fork tube into the lower fork

bracket, then the upper fork bracket.

NOTE

There is no specification to the loca-

tion of the top of the fork tube. How-

ever, as a guideline, set the fork tube

approximately 0.08 in (2.0 mm) above

the top surface of the upper fork

bracket (Figure 31).

17. With the fork assembly in the correct location,

tighten the upper and lower bracket pinch bolts to

the specification in Table 2.

10

18. Install the front wheel and front fender as de-

scribed in Chapter Nine.

Disassembly

Refer to Figure 37.

NOTE

A special fork holding tool is required

to disassemble and assemble this fork

assembly. The fork spring is so strong

that it cannot be compressed suffi-

1.

Rebound

11.

Dust seal

ciently by hand to gain access to the

adjuster

12.

Stopper ring

nut on top of the damper rod. This

2.

Fork cap bolt

13.

Oil seal

special tool is available from motor-

assembly

14.

Oil seal spacer

cycle dealerships or motorcycle parts

3.

O-ring

15.

Slider bushing

suppliers.

4.

Upper spacer

16.

Lower stop

5.

Spring collar

17.

Slider

6.

Lower spacer

18.

Compression

1. Hold the fork in a vertical position and com-

7.

Fork spring

damper adjuster

pletely unscrew the fork cap bolt from the fork tube.

8.

Damper

19.

Nut

The cap bolt cannot be removed at this time as it is

rod/cartridge

20.

Lockwasher

still attached to the damper rod cartridge.

assembly

21.

Washer

9.

Fork tube and

22.

Clamping bolt

2. Turn the fork assembly upside down and drain

bushing

23.

Washer

the residual fork oil into a suitable container. Pump

10.

Dust seal cover

24.

Allen bolt

the fork several times by hand to expel most of the

oil. Dispose of the fork oil properly.

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418

CHAPTER TEN

38

39

3. Install the lower end of the fork assembly in the

fork holding tool, following the manufacturer’s in-

40

structions. Make sure the tool is indexed properly in

the lower hole in the slider (Figure 38).

4. Slide the fork tube down into the fork slider to

expose the spring collar.

5. Install the special tool’s upper bolt into the hole

in the spring collar (Figure 39) following the manu-

facturer’s instructions. Make sure the tool is in-

dexed properly in the hole in the spring spacer.

6. Slowly tighten the special tool and compress the

fork assembly until the upper portion of the damper

rod cartridge and nut are exposed (Figure 40).

7. Install an open end wrench on the damper rod

41

cartridge nut (A, Figure 41) and another one on the

flats on the fork cap bolt (B, Figure 41).

8. Hold onto the cap bolt and loosen the damper rod

cartridge nut.

9. Completely unscrew the cap bolt from the

damper rod cartridge.

10. Measure the distance between the top of the

damper rod nut and the top of the damper rod car-

tridge (Figure 42). Note the dimension as it will be

used during assembly.

11. Withdraw the fork cap bolt (A, Figure 43) and

inner rod (B) from the damper rod cartridge.

12. Slowly loosen the special tool and release the

42

spring pressure within the fork assembly.

13. Remove the fork assembly from the special

tool.

14. Remove the upper spacer, spring collar and

lower spacer from above the fork spring.

15. Withdraw the fork spring and damper rod car-

tridge.

16. Slide the slider bushing, spacer, oil seal, retain-

ing ring, dust seal and cover from the fork tube.

Keep them in the order of removal (Figure 44).

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FRONT SUSPENSION AND STEERING

419

43

47

NOTE

44

Do not remove the fork tube bushing

unless it is going to be replaced. In-

spect it as described in this chapter.

17. Do not try to remove the lower stop in the base

of the slider. It is pressed into place. If necessary,

have a Harley-Davidson dealership remove it and

install a new one.

18. Inspect the components as described in this

chapter.

10

Inspection

45

Replace any damaged or excessively worn com-

ponents. Repair damaged threads with an appropri-

ately sized metric tap or die. Simply cleaning and

reinstalling unserviceable components will not im-

prove performance of the front suspension.

1. Thoroughly clean all parts in solvent and dry

them. Check the fork tube for signs of wear or

scratches.

2. Check the damper rod cartridge for straightness

and damage (Figure 45).

3. Check the threads and nut (Figure 46) at the top

of the damper rod cartridge for damage.

46

4. Make sure the oil hole (A, Figure 47) in the

damper rod cartridge is clear. Clean out if necessary.

5. Inspect the damper rod cartridge threads for the

Allen bolt (B, Figure 47) for wear or damage.

NOTE

Do not disassemble the fork cap bolt

and rebound adjuster (Figure 48).

Replacement parts are not available.

If this component is defective, replace

the unit as an assembly.

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