Content .. 20 21 22 23 ..

Harley Davidson 1999-2005 Harley Dyna Models. Repair Manual - page 22

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420

CHAPTER TEN

6. Inspect the fork cap bolt threads (A, Figure 49)

for wear or damage.

7. Install a new O-ring (B, Figure 49) on the fork

cap bolt.

8. Inspect the needle tip (Figure 50) on the end of

the fork cap bolt and inner rod for damage.

9. Check the fork tube (A, Figure 51) for straight-

ness. Refer to Table 3 for maximum runout.

10. Inspect the fork cap bolt threads in the fork tube

(Figure 52) for wear or damage.

11. Make sure the oil hole (Figure 53) in the fork

tube is clear. Clean out if necessary.

12. Check the slider (B, Figure 51) for dents or ex-

terior damage that may cause the upper fork tube to

stick.

13. Inspect the brake caliper mounting bosses (Fig-

ure 54) on the slider for cracks or other damage.

14. Check the front axle bore (Figure 55) in the

slider for burrs or damage.

15. Check the compression damping adjuster (Fig-

ure 56). Make sure it can be turned from one stop to

the other.

16. Inspect the oil seal seating area (Figure 57) in

the slider for damage or burrs.

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FRONT SUSPENSION AND STEERING

421

17. Inspect the slider bushing (A, Figure 58) and

fork tube bushing (B). If either is scratched or

scored, they must be replaced.

18. Measure the uncompressed length of the fork

spring as shown in Figure 59. Replace the spring if

it has sagged to the service limit listed in Table 3.

Assembly

1. Coat all parts with clean H-D Type E fork oil

prior to installation.

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422

CHAPTER TEN

2. If removed, install a new bushing (Figure 60)

onto the fork tube.

NOTE

Place a clinging-type plastic wrap

over the end of the slider and coat it

with fork oil. This will prevent dam-

age to the dust seal and the oil seal

lips when installing them over the top

of the fork tube. The parts can then be

carefully slid over the fork tube and

the plastic wrap without damaging

the seal.

3. Coat the new seal with clean fork oil.

NOTE

Position the new oil seal with the open

groove facing upward.

4. Slide the fork slider bushing (A, Figure 61),

spacer (B), oil seal (C), stopper ring (D), dust seal

(E) and cover (F) down into the fork tube.

5. Insert the damper rod cartridge into the fork tube

(Figure 62).

NOTE

The slider bushing opening must be

positioned to either side of the slider

after the fork tube has been installed.

Orientate the opening in relation to

the front fender mounting bosses. If

the opening is positioned toward ei-

ther the front or rear of the slider, it

will wear prematurely.

6. Position the slider bushing with the opening

(Figure 63) toward either side of the slider.

7. Insert the fork tube into the slider until the slider

bushing reaches the slider.

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FRONT SUSPENSION AND STEERING

423

8. Once again make sure the slider bushing open-

ing (A, Figure 64) is correctly located in relation to

the fender bosses (B). Readjust if necessary.

NOTE

A fork seal driver like is required to in-

stall the fork tube bushing and seal into

the fork tube. A number of different af-

termarket fork seal drivers are avail-

able that can be used for this purpose.

Another method is to use a piece of pipe

or metal collar with correct dimensions

to slide over the fork tube and seat

against the seal. When selecting or fab-

ricating a driver tool, it must have suffi-

cient weight to drive the bushing and oil

seal into the fork tube. A fork seal and

cap installer (JIMS part No. 2046) is

used in this procedure.

9. Slide the fork seal driver down the fork tube and

seat it against the seal (C, Figure 64).

10. Operate the driver and drive the fork slider

bushing, spacer and new seal into the fork tube.

Continue until the fork tube stopper ring groove is

visible above the fork seal (Figure 65).

11. Slide the stopper ring down the fork tube.

12. Install the stopper ring and make sure it is com-

pletely seated in the groove in the fork slider (Fig-

ure 66).

13. Install the dust seal into the slider. Index it into

the groove in the slider (Figure 67).

14. Install the cover and carefully tap it into place

(Figure 68).

15. Insert the damper rod cartridge into the fork

tube (Figure 69).

NOTE

The lower end of the damper rod car-

tridge must be guided into the lower

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424

CHAPTER TEN

stop in the base of the slider. If not

aligned correctly, the Allen bolt can

not be installed in Step 16.

16. Insert a scribe or thin screwdriver into the hole

in the base of the slider to guide the lower end of the

damper rod cartridge into the lower stop in the base

of the slider.

NOTE

If the damper rod cartridge rotates

while tightening the Allen bolt, tem-

porarily install the fork spring and the

cap bolt to hold it stationary.

17. Install a new washer on the Allen bolt (Figure

70). Install it in the fork slider and tighten to the

specification in Table 1. If installed, remove the cap

bolt and fork spring.

NOTE

The following special tool is usually

part of the fork holding tool. If not so

equipped, one can be fabricated that

is approximately 2 inches long with

an inner metric thread of 12 ×1.0.

This tool is to extend the length of the

damper rod for fork bleeding process.

18. Install the special tool extension (Figure 71)

onto the damper rod cartridge.

19. Secure the fork assembly in a vertical position.

NOTE

To measure the correct amount of

fluid, use a plastic baby bottle. These

bottles have measurements in millili-

ters (ml) on the side.

20. Completely compress the fork tube into the

slider.

21. Add one-half of the recommended amount (Ta-

ble 2) of H-D Type E fork oil to the fork assembly

(Figure 72).

NOTE

During the bleeding procedure, main-

tain the fork oil level above the sliding

portion of the damper rod cartridge. If

the oil level drops below this level, air

may enter the cartridge, nullifying the

bleeding procedure.

22. Bleed air from the damper rod cartridge as fol-

lows:

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FRONT SUSPENSION AND STEERING

425

Hold the fork assembly in a vertical position

and hold it this way during this step.

Hold on to the special tool extension installed

in Step 18 and slowly move the damper rod

cartridge up and down (Figure 73) using full

travel strokes.

Repeat this at least ten times, or until the fork

oil is free of bubbles.

If necessary, add additional fork oil until the

oil is almost level with the top of the com-

pressed fork tube.

Slowly move the fork tube up and down sev-

eral strokes or until bubbles do not come from

the oil.

Secure the fork assembly in this vertical posi-

tion for 5-10 minutes to allow any additional

trapped air to escape. Tap on the side of the

fork assembly to break away any bubbles ad-

Rebound

hering to the side of the fork.

damping

adjuster

Add the remaining amount of the fork oil.

Fork

NOTE

tube

Harley-Davidson recommends that

the fork oil level be measured, if possi-

ble, to ensure a more accurate filling.

Piston

Fork oil level

23. Adjust the fork oil as follows:

rod

a. Hold the fork assembly vertically, and fully

compress the fork tube.

b. Use an accurate ruler or the Motion Pro oil

gauge (part No. 08-0121) (Figure 74), or an

equivalent, to achieve the oil level listed in

Table 3.

c. Allow the oil to settle completely and recheck

the oil level measurement (Figure 75). Ad-

just the oil level if necessary.

d. Remove the special tools.

24. Fully extend the fork tube.

25. Position the fork spring with the closer wound

coils (Figure 76) going in first and install the fork

spring.

26. Keeping the fork assembly upright so the fork

oil will not drain out, slightly compress the fork so

the top of the damper rod is extended up through the

top of the spring.

27. Position the lower spacer with the sharp side

facing UP and install it (Figure 77).

28. Install the spring collar (Figure 78) with the

hole toward the spring.

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

fork holding tool (Figure 38), following the manu-

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426

CHAPTER TEN

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

dexed properly in the lower hole in the slider.

30. Install the special tool upper bolt into the hole

in the spring spacer (A, Figure 79), following the

manufacturer’s instructions. Make sure the tool is

indexed properly in the hole in the spring spacer.

31. Slowly tighten the special tool and compress

the fork assembly until the damper rod cartridge nut

is slightly above the spring spacer (B, Figure 79).

32. Unscrew and remove the special tool extension

(C, Figure 79) from the damper rod cartridge.

33. Correctly position the nut down from the top of

the damper rod cartridge (Figure 80) to the dimen-

sion noted in Disassembly Step 10.

34. Position the upper spacer with the sharp side

facing DOWN and install it (A, Figure 81).

35. Install the inner rod

(Figure

82) into the

damper rod cartridge.

36. Screw the fork cap bolt assembly (B, Figure

81) onto the damper rod cartridge until the rebound

damping force adjuster, within the fork cap bolt,

seats on the inner rod.

37. Install an open end wrench on the flats on the

cap bolt

(A, Figure

83) and another onto the

damper rod nut (B, Figure 83).

38. Hold onto the fork cap bolt and tighten the

damper rod nut against it securely. Remove the

wrenches.

39. Slowly loosen the special tool and disconnect

the upper portion of the tool from the spring spacer.

40. Remove the fork assembly from the special

tool.

41. Pull the fork tube (A, Figure 84) up against the

fork cap bolt (B) and screw the cap bolt into the fork

tube and tighten securely. Do not try to tighten to the

final torque at this time.

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FRONT SUSPENSION AND STEERING

427

42. Install the fork assemblies as described in this

chapter and tighten the cap bolt to the specification

in Table 1.

FRONT SUSPENSION ADJUSTMENT

(FXDXT, 2000-ON FXDX)

Rebound Damping Force Adjustment

The rebound damping can be adjusted by turning

the knob adjuster on top of the fork cap bolt. The

knob adjuster has 17 positions.

The standard adjuster setting is eight turns out

from the base position. Turning the adjuster all the

way clockwise results in the stiffer setting, while

turning the adjuster counterclockwise results in the

softer setting.

1. Turn the knob adjuster (Figure 85) in either di-

rection to achieve the desired rebound damping.

2. Turning the adjuster clockwise will increase re-

bound damping.

3. Turning the adjuster counterclockwise will de-

crease rebound damping.

4. Repeat for the other fork assembly. Ensure both

fork legs are adjusted to the same setting.

Compression Damping Force Adjustment

The compression damping force can be adjusted

by turning the screw adjuster on the base of the fork

slider. The knob adjuster has 14 positions.

The standard adjuster setting is ten turns out from

the base position.

1. Turn the adjuster (Figure 86) and rotate it in ei-

ther direction to achieve the desired compression

damping force adjustment.

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428

CHAPTER TEN

2. Turning the adjuster clockwise will increase

compression damping force.

STEERING STEM (ALL

MODELS EXCEPT FXDWG)

3. Turning the adjuster counterclockwise will de-

crease compression damping force.

4. Repeat for the other fork assembly. Ensure both

fork legs are adjusted to the same setting.

STEERING HEAD

AND STEM

Removal

(All Models Except FXDWG)

Refer to Figure 87.

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

scribed in Chapter Nine.

2. Remove the fuel tank (A, Figure 88) as de-

scribed in Chapter Seven.

3. Remove the brake hose union from the bottom of

the lower fork bracket (B, Figure 88). Do not dis-

connect any brake hose connections.

4. Remove the headlight mounting bracket bolt and

remove the bracket (Figure 89) from the upper fork

bracket.

5. Remove the two front handlebar clamp bolts and

washers or collars. Then set the instrument housing

forward (A, Figure 90) so that it does not scratch

the handlebar clamp.

6. Remove the two rear clamp bolts, then remove

the holder (B, Figure 90) and handlebars.

7. Unscrew and remove the cap (C, Figure 90)

from the steering stem bolt.

8. Remove the front fork legs (A, Figure 91) as de-

scribed in this chapter.

9. Loosen the steering stem pinch bolt (B, Figure

91).

Cap

Bolt

Washer

NOTE

Upper bracket

Hold or secure the steering stem to

Screw

keep it from falling after removing the

Clamp bolt

steering stem bolt in Step 10.

Upper dust seal

Upper bearing

10. Remove the steering stem bolt (C, Figure 91)

Upper bearing outer race

and washer. Then lift the upper fork bracket off the

10.

Lower bearing outer race

steering stem and lower the steering stem out of the

11.

Lower bearing

12.

Lower dust seal

frame and remove it.

13.

Steering stem/lower

11. Remove the upper dust shield and bearing.

bracket

12. Inspect the steering stem and bearing assembly

14.

Snap ring

as described under Inspection (All Models) in this

15.

Clamp bolt

section.

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FRONT SUSPENSION AND STEERING

429

Installation

(All Models Except FXDWG)

1. Make sure to seat the steering head bearing races

in the frame.

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. Install the lower bearing and lower dust

shield on the steering stem before installing the

steering stem in the frame. If necessary, install the

lower bearing as described in this chapter.

4. Insert the steering stem into the frame steering

head and hold it firmly in place.

5. Install the upper bearing over the fork stem and

seat it into to the upper race. Install the upper dust

shield.

6. Install the upper fork bracket over the steering

stem.

7. Install the washer and the steering stem bolt (C,

Figure 91). Tighten the bolt hand-tight only.

8. Install the front fork legs (A, Figure 91) as de-

scribed in this chapter.

CAUTION

Do not overtighten the steering stem

bolt in Step 9 or damage will occur to

the bearings and races. Final adjust-

ment of the fork stem will take place

after the front wheel is installed.

9. Tighten the steering stem bolt (C, Figure 91) un-

til the steering stem can be turned from side to side

with no noticeable axial or lateral play. When the

play feels correct, tighten the steering stem pinch

bolt (B, Figure 91) to the specification in Table 1.

10. Install the handlebar and tighten the clamp

bolts as described in this chapter.

11. Install the headlight mounting bracket (Figure

89) onto the upper fork bracket. Tighten the mount-

ing bolts securely.

12. Install the brake hose union onto the bottom of

the lower fork bracket (B, Figure 88). Tighten the

bolt securely.

13. Install the front wheel as described in Chapter

Nine.

14. Install the fuel tank (A, Figure 88) as described

in Chapter Seven.

15. Adjust the steering play as described under

Steering Play Adjustment in this chapter.

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CHAPTER TEN

Removal

(FXDWG)

STEERING STEM (FXDWG)

Refer to Figure 92.

1. Remove the front wheel as described in Chapter

Nine.

2. Remove the fuel tank as described in Chapter

Seven.

3. Remove the brake hose union from the bottom of

the lower fork bracket. Do not disconnect any brake

hose connections.

4. Remove the headlight mounting bracket bolt and

remove the bracket from the fork bracket.

5. Remove the two front handlebar clamp bolts and

washers or collars. Then set the instrument housing

forward so that it does not scratch the handlebar

clamp.

6. Remove the two rear clamp bolts, then remove

the holder and handlebar.

7. Unscrew and remove the cap from the steering

stem nut.

8. Remove the front fork legs as described in this

chapter.

9. Bend the lockwasher tab away from the steering

stem nut, then remove the nut and lockwasher.

10. Lift the upper fork bracket off the steering stem

and remove it.

NOTE

Make sure to hold or secure the steer-

ing stem/lower fork bracket. This will

prevent it from falling after removing

the steering stem adjust nut in Step 11.

Cap

11. Loosen and remove the adjust nut. Then lower

Nut

the steering stem assembly out of the frame and re-

Lockwasher

move it.

Upper bracket

Clamp bolt

12. Remove the upper dust shield and upper bear-

Adjust nut

ing.

Upper dust seal

13. Inspect the steering stem and bearing assembly

Upper bearing

as described under Inspection (All Models) in this

Upper bearing outer race

section.

10.

Lower bearing outer race

11.

Lower bearing

12.

Lower dust seal

Installation (FXDWG)

13.

Steering stem/lower

bracket

14.

Bolt

1. Make sure the steering head bearing races are

15.

Washer

seated in the frame.

16.

Circlip

2. Wipe the bearing races with a clean lint-free

17.

Pad

cloth. Then lubricate each race with bearing grease.

18.

Headlight mounting

3. Pack the upper and lower bearings with bearing

bracket

grease. Install the lower bearing and the lower dust

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FRONT SUSPENSION AND STEERING

431

shield onto the steering stem before installing the

1. Wipe the bearing races with a solvent-soaked rag

steering stem in the frame. If necessary, install the

and then dry with compressed air or a lint-free cloth.

lower bearing as described in this chapter.

Check the races in the steering head for pitting,

4. Insert the steering stem into the frame and hold it

scratches, galling or excessive wear. If any of these

firmly in place.

conditions exist, replace the races as described in

5. Install the upper bearing over the fork stem and

this chapter. If the races are good, wipe each race

seat it into to the upper race. Install the upper dust

with grease.

shield.

2. Clean the bearings in solvent to remove all of the

old grease. Blow the bearing dry with compressed

CAUTION

air, making sure not to allow the air jet to spin the

Do not overtighten the adjust nut in

bearing. Do not remove the lower bearing from the

Step 6 or the bearings and races will be

fork stem unless it is to be replaced. Clean the bear-

damaged. Final adjustment of the fork

ing while installed in the steering stem.

stem will take place after the front

3. After the bearings are dry, hold the inner race

wheel is installed on the motorcycle.

with one hand and turn the outer race with the other

6. Thread the adjust nut onto the steering stem.

hand. Turn the bearing slowly, the bearing must turn

Tighten the adjust nut until the steering stem can be

smoothly with no roughness. Visually check the

turned from side to side with no noticeable axial or

bearing for pitting, scratches or visible damage. If

lateral play. The steering stem must turn with no

the bearings are worn, check the dust covers for

binding or roughness.

wear or damage or for improper bearing lubrication.

7. Install the upper fork bracket over the steering

Replace the bearing if necessary. If a bearing is go-

stem.

ing to be reused, pack it with grease and wrap it with

8. Install a new lockwasher over the steering stem.

wax paper or some other type of lint-free material

Engage the lockwasher pin into the hole in the up-

until it is reinstalled. Do not store the bearings for

per fork bracket. Then install the steering stem nut.

any length of time without lubricating them or they

Tighten the steering stem nut securely.

will rust.

9. Install the front fork legs as described in this

4. Check the steering stem for cracks or damage.

chapter.

Check the threads at the top of the stem for damage.

10. Install the handlebar and tighten the clamp

Check the steering stem bolt or nut for damage.

bolts as described under Handlebar Removal/In-

Thread it into the steering stem; make sure the bolt

stallation in this chapter.

threads easily with no roughness.

11. Install the headlight mounting bracket onto the

5. Replace all worn or damaged parts. Replace

fork bracket. Tighten the mounting bolts securely.

bearing races as described in this chapter.

12. Install the brake hose bracket onto the bottom

6. Replace the lower steering stem bearing and the

of the lower fork bracket. Tighten the brake hose

dust shield as described in this chapter.

bracket bolt to the specification in Table 1.

7. Check for broken welds on the frame around the

13. Install the front wheel as described in Chapter

steering head. If any are found, have them repaired

Nine.

by a competent frame shop or welding service fa-

14. Adjust the steering play as described under

miliar with motorcycle frame repair.

Steering Play Adjustment in this chapter.

15. Tighten the steering stem nut to the specifica-

STEERING HEAD BEARING RACE

tion in Table 1. Bend the lockwasher tab against

REPLACEMENT

one nut flat.

16. Install the cap onto the steering stem nut.

The upper and lower bearing outer races are

pressed into the frame. Do not remove the bearing

Inspection

races unless replacement is necessary. If removed,

(All Models)

replace both the outer race along with the bearing at

the same time. Never reinstall an outer race that has

The bearing outer races are pressed into the steer-

been removed as it is no longer true and will dam-

ing head.

age the bearing if reused.

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432

CHAPTER TEN

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 93). Tap all around the

race so that neither the race nor the steering head is

bent.

3. Clean the steering head with solvent and dry

thoroughly.

4A. Install the bearing races with a steering head

bearing race installer tool (JIMS part No. 1725), fol-

lowing the manufacturer’s instructions.

4B. If the special tools are not available, install the

bearing 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.

Make sure not to contact the bearing race sur-

faces. See Figure 94. Drive the race into the

steering head until it bottoms out on the bore

shoulder.

c. Repeat to install the lower race into the steer-

ing 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 seal unless it is 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 and have them remove

it and reinstall a new part.

Never reinstall a lower bearing that has been re-

moved as it is no longer true and will damage the

rest of the bearing assembly if reused.

Wood

1. Install the steering stem bolt onto the top of the

block

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

Race

in Figure 95. Slide the lower bearing and grease

seal off the steering stem.

3. Clean the steering stem with solvent and dry

Head

tube

thoroughly.

4. Position the new lower dust seal with the flange

side facing up.

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FRONT SUSPENSION AND STEERING

433

Stem nut

Steering stem

Chisel

Hollow pipe

Bearing

Dust seal and bottom race

5. Slide a new grease seal and the lower bearing

3. Apply a strip of masking tape across the front

onto the steering stem until it stops on the raised

end of the front fender. Draw a vertical line across

shoulder.

the tape at the center of the fender.

4. Turn the handlebar so that the front wheel faces

6. Align the lower bearing with the machined

straight ahead.

shoulder on the steering stem. Press or drive the

5. Install a pointer so the base is stationary on the

lower bearing onto the steering stem until it bottoms

floor and the pointer indicates the center of the fender

(Figure 96).

tape mark when the wheel is facing straight ahead.

6. Loosen the lower bracket pinch bolt on both fork

tubes.

STEERING PLAY ADJUSTMENT

7. Lightly push the fender toward the right side un-

til the front end starts to turn by itself. Mark this

1. Support the motorcycle with the front wheel off

point on the tape.

the ground. See Motorcycle Stands in Chapter Nine.

8. Repeat Step 6 for the left side.

2. On models so equipped, remove the windshield,

9. Measure the distance between the 2 marks on the

as described in Chapter Thirteen, and all other ac-

tape. The correct distance is 1-2 in. (25-50 mm). If

cessory weight from the handlebar and front fork

the distance is incorrect, perform Step 10.

that could affect this adjustment.

10. Loosen or tighten the steering stem nut or bolt

until the measurement is within the limits.

NOTE

11. Tighten the lower fork bracket pinch bolts to

If a control cable affects handlebar

the torque specification in Table 1.

movement, disconnect it.

12. Reinstall all parts previously removed.

Table 1 FRONT SUSPENSION TORQUE SPECIFICATIONS

Item

ft.-lb.

in.-lb.

N·m

Fork cap FXDX, FXDXT

22-29

30-39

Fork cap screw FXDX,

FXDXT

22-29

30-39

Fork slider tube cap

FXDWG

11-22

15-30

All models

except FXDWG

11-22

15-30

Upper fork bridge

pinch bolt

FXDWG

21-27

29-37

(continued)

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434

CHAPTER TEN

Table 1 FRONT SUSPENSION TORQUE SPECIFICATIONS (continued)

Item

ft.-lb.

in.-lb.

N·m

Upper and lower fork

bracket pinch bolts

All models

except FXDWG

25-30

34-41

Steering stem

Bolt (all models

except FXDWG)

21-27

29-37

Nut (FXDWG)

35-40

47-54

Brake hose bracket bolt

132

Front fender nuts

FXDWG

15-21

20-28

All models

except FXDWG

120-168

14-19

Table 2 FRONT FORK OIL CAPACITY AND OIL LEVEL DIMENSIONS

Model

Capacity oz. (ml)

Oil level dimension

1999 models

FXDWG

10.2 (302)

All models except FXDWG

9.2 (272)

2000-on models

FXD

10.6 (314)

6.69

(169.9)

FXDS-CONV

11.5 (341)

6.10

(154.9)

FXDWG

12.0 (356)

7.28

(184.9)

FXDX, FXDXT

See text procedure

FXDP

2000-2001

FXDL

10.7 (316)

7.20

(182.0)

2002-on

FXDL

10.6 (304)

6.69

(169.9)

NA = Information not available from the manufacturer.

Table 3 FRONT FORK SPECIFICATIONS (FXDXT AND 2000-ON FXDX)*

Fork spring minimum length

17.0 in. (431.8 mm)

Fork tube maximum runout

0.008 in. (0.2 mm)

*Service specifications for all other fork assemblies are not available from the manufacturer.

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CHAPTER ELEVEN

REAR SUSPENSION

This chapter describes repair and replacement

SHOCK ABSORBERS

procedures for the rear suspension components. Re-

fer to Table 1 at the end of this chapter for torque

The shock absorbers are spring controlled and hy-

specifications.

draulically damped. Spring preload is adjustable on

all models and the rebound compression is also ad-

justable on FXDX and FXDXT models. Refer to

WARNING

Shock Absorber Adjustment in this chapter.

All nuts and bolts used on the rear

suspension must be replaced with

parts of the same type. Do not use a

Removal/Installation

replacement part of lesser quality or

substitute design, as it may affect the

When servicing the rear shocks, remove one

performance of the rear suspension or

shock at a time. If it is necessary to remove both

fail, leading to loss of control of the

shocks, support the motorcycle with the rear wheel

motorcycle. The torque specifications

off the ground.

listed in Table 1 must be used during

installation to ensure proper retention

1. Support the motorcycle with the rear wheel off

of these components.

the ground. See Motorcycle Stands in Chapter Nine.

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436

CHAPTER ELEVEN

2. Place wooden blocks under the rear wheel to

place the rear wheel in a neutral position with no

strain on the shock absorber mounting hardware.

3A. On FXDX and FXDXT models, perform the

following:

a. Remove the upper acorn nut and washer (A,

Figure 1) securing the shock absorber to the

frame shock stud.

b. Remove the lower acorn nut and washer (B,

Figure 1) securing the shock absorber to the

swing arm mounting bracket.

c. Pull the shock absorber straight off the frame

upper stud and remove the shock absorber.

3B. On all models except FXDX and FXDXT, per-

form the following:

a. Remove the upper acorn nut and washer (A,

Figure 2) securing the shock absorber to the

frame shock stud.

b. Remove the lower acorn nut and washer (Fig-

ure 3) securing the shock absorber to the

swing arm mounting bracket.

c. On models so equipped, remove the chrome

cover (B, Figure 2).

d. Pull the shock absorber straight off the frame

upper stud and remove the shock absorber.

4. Check the upper shock stud (Figure 4) for loose-

ness. Securely tighten if necessary.

5. Repeat for the other shock absorber if necessary.

6. Inspect the shock absorber as described in this

chapter.

7. Install the shocks by reversing these removal

steps while noting the following:

a. Apply a few drops of ThreeBond TB1342 or

an equivalent to the shock stud and bolt

threads.

b. Install the washers and nuts and tighten to the

specification in Table 1.

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REAR SUSPENSION

437

c. Adjust the shock absorbers as described in

this chapter.

d. Lower the motorcycle and test ride it to make

sure the rear suspension is working properly.

Inspection

(FXDX and FXDXT Models)

There are no shock replacement parts available

for these models. If any part other than the mount-

ing hardware is damaged, replace the shock assem-

bly.

1. Remove the shock absorber as described in this

chapter.

2. Inspect the upper shock bushing (Figure 5) and

lower shock bushing (Figure 6) for wear and deteri-

oration.

3. Inspect the shock absorber. If the damper hous-

ing (A, Figure 7) is leaking, bent, or in any way

damaged, replace the shock absorber.

4. Inspect the shock spring (B, Figure 7), spring re-

tainer, cover and spring adjust cam for cracks or

damage.

5. Note the existing setting of the rebound adjuster.

6. Rotate the rebound adjuster (Figure 8) through

all of its ten settings. Make sure the adjuster rotates

freely and engages the detent in each position. Re-

turn the adjuster to the setting noted in Step 5.

Inspection

(All Models Except FXDX and FXDXT)

1. Remove the shock absorber as described in this

chapter.

2. Inspect the upper shock bushing (A, Figure 9)

and lower shock bushing (A, Figure 10) for wear and

deterioration. Replace worn or damaged bushings.

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438

CHAPTER ELEVEN

REAR SHOCK ABSORBER

3. Inspect the shock absorber. If the damper hous-

ing (A, Figure 11) is leaking, bent, or in any way

damaged, replace the shock absorber.

4. Inspect the shock spring (B, Figure 11), spring

retainer, cover and cam for cracks or damage. If

necessary, replace the shock spring as described in

this section.

Shock Bushing Inspection and Replacement

(All Models Except FXDX and FXDXT)

Refer to Figure 12.

Replace both bushings at the same time.

1. Remove the shock absorber as described in this

chapter.

CAUTION

When supporting the shock absorbers

in a press in Step 2, position the press

blocks or other equipment so that they

do not dent or otherwise damage the

damper body.

2. Support the shock absorber in a press and press

Spring retainer

Upper case

out the bushing.

Spring

3. Repeat for the bushing on the other end.

Spring guide

4. Clean the shock eyelets of all rust and rubber res-

Spring adjuster cam

Cam sleeve

idue. Then check the eyelets for cracks, burrs, dents

Nut

and other problems. Replace the shock absorber if

Lockwasher

damaged.

Washer

10.

Bolt (frame mount)

NOTE

11.

Bushing

The upper and lower shock bushings

12.

Shock cover

are identical.

13.

Acorn nut

14.

Bolt

15.

Screw

5. Align the new bushing with the shock eyelet and

16.

Damper housing

start it into place. Then support the shock absorber

in a press and press the bushing into place, centering

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REAR SUSPENSION

439

retainer to fly off, causing severe per-

sonal injury.

4. Compress the spring and remove the spring re-

tainer (B, Figure 9). Then release spring tension

and remove the shock absorber from the tool. Com-

plete the disassembly by removing the parts in the

order shown in Figure 12.

5. Spring free length specifications are not avail-

able. If the spring has sagged, remove the other

shock spring and compare the length of both

springs. Replace both springs if one is shorter than

the other one.

6. Inspect the spring adjuster for cracks, excessive

wear or other damage.

7. Assemble by reversing these disassembly steps,

while noting the following:

a. Make sure the spring retainer (B, Figure 9) is

seated correctly in the cover (C, Figure 9) be-

fore releasing the pressure of the spring com-

pressor tool.

b. Adjust the spring pre-load as described in this

chapter.

it in the shock eyelet. Repeat for the bushing in the

SHOCK ABSORBER ADJUSTMENT

other end.

Spring Preload Adjustment

Spring Removal/Installation

(All Models Except FXDX and FXDXT)

The ride height (height of a motorcycle at rest

with no rider or passenger) can be adjusted with the

A spring compressor is required to remove and

cam preload adjuster at the base of each shock

install the shock spring. When servicing aftermar-

spring (B, Figure 10). Turning the cam adjuster to

ket shocks, follow the manufacturer’s instructions.

the five different steps moves the cam ramps up or

Refer to Figure 12.

down, either compressing or extending the spring.

1. Remove the shock absorber as described in this

Increasing the cam angle increases the spring load

chapter.

and raises the ride height. Spring preload also con-

2. Rotate the spring adjuster cam to the lowest set-

trols how far the shock absorber compresses under

ting to reduce the amount of spring pressure on the

the weight of the motorcycle and rider.

shock absorber.

Select the position that best suits the vehicle load

3. Mount the shock absorber in a spring compres-

requirements. The cam positions range from the No.

sor tool (Figure 13).

1 for a rider with no luggage to the No. 5 consisting

of the maximum allowable GVWR loads listed in

WARNING

the owner’s manual. The standard factory setting is

Do not attempt to remove the spring

the third cam step position.

from the shock absorber without a

Rotate the cam

(Figure

14) with a spanner

spring compressor. Because the

spring is under considerable pres-

wrench to compress the spring (heavy loads) or ex-

sure, using makeshift tools or incor-

tend the spring (light loads). Set the cam on both

rect procedures may allow the spring

shock absorbers to the same preload position.

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