3.22 Front Fork
Fragment manuala — str. 131–146
📋 Tekst do skopiowania (OCR/wyszukiwanie)
FRONT FORK 3.22
CHECK FOR OIL LEAK Check Oil Leak
1. Observe oil ring.
Fork Oil Seals
2. Wipe fork clean.
The fork oil seal allows a fine film of oil to lubricate the fork
sliding surface. 3. Ride motorcycle over bumpy road or complete six braking
events.
• The oil film is more visible after continuous high-speed
4. See Figure 3-58. Check fork slider tube for oil.
compression and rebound movement.
• Due to greater lubrication needs, larger forks have a greater a. If a normal oil/dust film (1, 2) is present, there is no leak.
amount of oil film than smaller forks. b. If an oil run or drip (3) is present, perform procedure
two or three more times to confirm oil leak.
1. Normal oil/dust film 3. Drip
2. Normal oil/dust film
Figure 3-58. Front Forks
PREPARE INSTALL
1. Raise front wheel. See Secure the Motorcycle for Service PART NUMBER TOOL NAME
in GENERAL (Page 2-2). HD-48650 DIGITAL TECHNICIAN II
2. Remove fairing. See FAIRING (Page 3-89). FASTENER TORQUE VALUE
Fork bracket, lower, pinch 15-18 ft-lbs 20.4-25 N·m
3. Remove front fender. See FRONT FENDER (Page 3-102). screw
Fork bracket, upper, pinch 15-18 ft-lbs 20.4-25 N·m
4. Detach front brake calipers. See FRONT BRAKE CALIPER screw
(Page 3-32).
1. See Figure 3-59. Install front fork tube assemblies.
5. Remove front wheel. See FRONT WHEEL (Page 3-8).
a. Insert each fork tube assembly (5) through lower fork
REMOVE bracket (6) and upper fork bracket (2).
b. Measure distance (1) from top of fork tube to top of
1. If equipped: Disconnect electrical connectors. lower fork bracket (3) to set fork height. Refer to
Table 3-9.
2. See Figure 3-59. Remove front fork tube assemblies.
c. Tighten lower fork bracket pinch screws (5)
a. Loosen lower pinch screws (4). alternately (top fastener, bottom fastener, repeat)
until specification is maintained.
b. Loosen upper pinch screws (3). Torque: 15-18 ft-lbs (20.4-25 N·m) Fork bracket,
lower, pinch screw
c. Remove fork tube assemblies (5).
94000784 3-53
d. Tighten upper fork bracket pinch screws (1 ). PART NUMBER TOOL NAME
Torque: 15-18 ft-lbs (20.4-25 N·m) Fork bracket, HD-59000-B HARLEY-DAVIDSON PRO-LEVEL OIL
upper, pinch screw GAUGE
2. If equipped: Connect electrical connectors. FASTENER TORQUE VALUE
NOTE Fork damper nut 13-17 ft-lbs 17.5-22.5 N·m
This is only required if a electrical component related to Fork tube cap, left side 22-30 ft-lbs 30--40 N·m
suspension or BCM is replaced. Fork tube damper screw, 133-221 in-lbs 15-25 N·m
standard
3. On the RA1250S and RA1250S with ARH the BCM will Front fork needle rod nut 22-30 ft-lbs 30-40 N·m
need to be recalibrated to learn the new values.
CONSUMABLE PART NUMBER
Special Tool: DIGITAL TECHNICIAN II (HD-48650)
HARLEY-DAVIDSON 11300005
Table 3-9. Fork Installation Distance SEAL GREASE
Distance T YPE "D" 62600098
Model (Side)''' HYDRAULIC FORK
RA1250 (Both) 8.65 in (219.7 mm) OIL
RA1250S Without Distance: 8.83 in (224.2 mm)
ARH (Both)
Disassemble
RA1250S With ARH Distance: 8.83 in (224.2 mm)
(Left)
Initial Disassembly
RA1250S With ARH Distance: 9.22 in (234.2 mm)
(Right) 1. See Figure 3-60. Clamp fork tube in fork tube holder. Mount
(1) Applies to both front and rear brake systems. in vise with fork vertical.
Special Tool: FORK T UBE HOLDER (HD-41177)
NOTE
Record compression and rebound settings.
2. Turn preload adjuster fully counterclockwise. See the
owner's manual.
3. NOTE
Have a suitable container ready to place components into
after removal from tube.
See Figure 3-65. Remove fork tube cap.
a. Loosen and separate fork tube cap (1) from fork tube
(11).
b. Compress fork assembly.
c. See Figure 3-61. Clamp front fork compressor
vertically in vise with length adjuster screw topside.
Special Tool: FRONT FORK COMPRESSOR
(HD-45966)
1. Distance d. Hold fork tube cap and compress spring enough to
2. Upper fork bracket access nut (1).
3. Upper fork bracket pinch screw
4. Lower fork bracket pinch sc rew (2) e. Loosen nut.
5. Fork tube assembly
6. Lower fork bracket f. Remove fork tube cap.
Figure 3-59. Front Fork Mount (typical)
4. Remove front fork compressor.
DISASSEMBLE AND ASSEMBLE:
STANDARD 5. See Figure 3-65. Discard O-ring (2).
PART NUMBER TOOL NAME
6. Remove spring seat stop (3).
B-48867 FORK SEAL DRIVER AND DUST BOOT
INSTALLER (47MM) 7. Remove rubber seat (5).
HD-41177 FORK TUBE HOLDER
HD-45966 FRONT FORK COMPRESSOR
3-54 94000784
8. Remove spring. Complete Disassembly
a. Remove spring collar (6). 1. See Figure 3-65. Remove damper.
b. Remove spring joint (7). a. Remove screw (19). Use an air impact wrench for
best results.
c. Remove spring (10).
b. Remove damper (8).
1096076
c. Remove centering plate (9).
2. Separate fork tube from fork slider.
a. Remove dust seal (17).
b. Remove stopper ring (16) from groove inside fork
tube (11).
c. Expand fork slider (18) and fork tube against each
other repeatedly (in a slide-hammer effect) to remove
fork tube.
3. Disassemble fork slider.
a. Remove slider bushing (12).
1. Fork tube holder
b. Remove guide bushing (13).
2. Fork tube
Figure 3-60. Fork Tube Holder C. Remove seal spacer (14).
1474717
d. Discard oil seal (15).
e. Remove stopper ring (16).
f. Remove dust seal (17).
Clean and Inspect
1. Clean all parts.
2. Inspect parts for wear or damage. Replace parts as
necessary.
3. Inspect OD of slider bushing and ID of fork tube bushing.
a. If coating is worn through (metallic substrate
showing), replace bushing.
b. Inspect for distortion.
c. If deep scratches or scoring are found, replace
bushing. Also inspect mating components for similar
1. Nut wear. Replace or repair as necessary.
Figure 3-61. Compress Fork Spring
4. Check fork tube and fork slider for scoring, scratches and
abnormal wear.
Drain Fork Oil
1. Drain fork oil. 5. Inspect slider tube for nicks from stones and road debris,
especially in area where seal contacts it. Replace if
a. Partially compress fork. necessary.
b. Pour oil into a suitable container 6. See Figure 3-62. Check runout with a dial indicator.
a. Set fork slider on V-blocks.
b. Replace fork if runout exceeds:
94000784 3-55
0.008 in (0.2 mm) NOTE
Set fork oil level with assembly fully compressed.
sm02901
a. Fill fork with fork oil.
T YPE "D" HYDRAULIC FORK OIL (62600098)
b. Pump fork slider (18) 8-10 times to expel air from
assembly.
NOTE
It is important that the pumping procedure is
performed.
Figure 3-62. Measure Fork Tube Runout c. Fully compress assembly.
Initial Assembly d. Fill fork with fork oil until oil is above specified depth
from top of fully compressed fork.
1. NOTE
Lubricate all seal lips and O-rings with seal grease during 4.17 in (106 mm)
assembly. HARLEY-DAVIDSON SEAL GREASE
e. Pump assembly 8-10 times to expel any additional
(11300005)
air.
See Figure 3-65. Assemble fork slider.
4. See Figure 3-63. Use fork oil level gauge to set oil level
to specified depth.
a. Install dust seal (17).
4.17 in (106 mm)
b. Install stopper ring (16). Special Tool: HARLEY-DAVIDSON PRO-LEVEL OIL
GAUGE (HD-59000-B)
c. Install new oil seal (15) with lettering facing down.
Complete Assembly
d. Install seal spacer (14).
NOTE
e. Install guide bushing (13). Install spring tapered end up.
f. Install slider bushing (12). Expand bushing only
enough to fit fork slider (18). 1. See Figure 3-65. Install spring (10).
g. Install centering plate (9) with damper (8). 2. Install spring joint (7).
h. Install new screw (19). T ighten. 3. Install spring collar (6).
Torque: 133-221 in-lbs (15-25 N·m) Fork tube
damper screw, standard 4. Install spring seat stop (3).
2. Assemble fork slider to fork tube.
5. Install rubber seat (5).
a. Slide fork slider into fork tube.
6. Install new O-ring (2).
b. Seat oil seal with installer.
7. Set needle rod gap.
Special Tool: FORK SEAL DRIVER AND DUST
BOOT INSTALLER (47MM) (B-48867)
a. See Figure 3-64. Loosen nuts (2 and 3).
c. Install stopper ring (16) into groove in fork tube.
b. Adjust needle rod (1) to achieve specified length (4).
d. Seat dust seal with installer.
0.06 in (1.5 mm)
Fork Fill c. Tighten nut (2).
Torque: 22-30 ft-lbs (30-40 N·m) Front fork needle
1. Mount fork assembly in fork tube holder and fully compress
rod nut
assembly.
Special Tool: FORK TUBE HOLDER (HD-41177) 8. See Figure 3-61. Compress fork using front fork
compressor.
2. Install damper rod extension from front fork compressor
Special Tool: FRONT FORK COMPRESSOR (HD-45966)
tool on damper rod.
NOTE
• Lubricate all seal lips and O-rings with
3. Bleed fork assembly.
HARLEY-DAVIDSON SEAL GREASE during assembly.
3-56 94000784
• Insert needle rod slowly into damper.
a. Compress spring enough to allow damper to be
raised above spring seat stop.
b. Remove extension tool while holding damper.
c. Fully install nut (1) on damper.
9. Install fork tube cap.
a. Fully install fork tube cap on damper.
b. Tighten nut (1) against fork tube cap.
Torque: 13-17 ft-lbs (17.5-22.5 N·m) Fork damper
nut
c. See Figure 3-65. Install fork tube cap (1). Tighten.
Torque: 22-30 ft-lbs (30-40 N·m) Fork tube cap, left
side
10. Adjust compression and rebound settings. See the owner's
manual.
sm01639a 1. Needle rod
2. Nut
3. Nut
4. Distance (1.5mm)
Figure 3-64. Needle Rod
1. Fork oil level
2. Tube
3. Collar
4. Thumb lock
Figure 3-63. Oil Level Gauge
1465785
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1. Fork tube cap 11. Fork tube
2. O-ring 12. Slider bushing
3. Spring seat stop 13. Guide bushing
4. Nut 14. Seal spacer
5. Rubber seat 15. Oil seal
6. Spring collar 16. Stopper ring
7. Spring joint 17. Dust seal
8. Damper 18. Fork slider
9. Centering plate 19. Screw
10. Spring
Figure 3-65. Fork Components, Base Model
DISASSEMBLE AND ASSEMBLE: LEFT CONSUMABLE PART NUMBER
SIDE. S MODELS. ALL HARLEY-DAVIDSON 11300005
SEAL GREASE
PART NUMBER TOOL NAME TYPE "D" 62600098
B-48867 FORK SEAL DRIVER AND DUST BOOT HYDRAULIC FORK
INSTALLER (47MM) OIL
HD-41177 FORK TUBE HOLDER LOCTITE 243 99642-97
HD-45966 FRONT FORK COMPRESSOR MEDIUM
STRENGTH
HD-50084-A FORK CAP WRENCH
THREADLOCKER
AND SEALANT
FASTENER TORQUE VALUE
(BLUE)
Fork pin retaining screw, left, 53-71 in-lbs 6-8 N·m
S models
Disassemble
Fork tube cap, left side, S 22-30 ft-lbs 30-40 N·m
models Initial Disassembly
Fork tube damper screw, left, 133-221 in-lbs 15-25 N·m
S models 1. See Figure 3-66. Clamp fork tube in fork tube holder. Mount
in vise with fork vertical.
S pecial Tool: FORK TUBE HOLDER (HD-41177)
3-58 94000784
2. See Figure 3-68. Loosen and separate fork tube cap from 3. Remove fork tube cap.
fork tube using fork cap wrench.
Special Tool: FORK CAP WRENCH (HD-50084-A) a. Remove screws (2).
3. Remove fork from fork tube holder. b. Remove pin (3).
C. Remove fork tube cap (1).
1096076
d. Discard O-ring (4).
4. Remove spring collar (5).
5. Remove spring (6).
6. Separate fork tube from fork slider.
a. Remove dust seal (16).
b. Remove stopper ring (15) from groove inside fork
tube (10).
c. Expand fork slider (17) and fork tube against each
other repeatedly (in a slide-hammer effect) to remove
fork tube.
1. Fork tube holder
2. Fork tube
7. Disassemble fork slider.
Figure 3-66. Fork Tube Holder
NOTE
Drain Fork Oil See Figure 3-69. Screws in front fork axle housing are not
serviceable and should not be removed.
1. Drain fork oil.
a. Remove slider bushing (11).
a. Partially compress fork.
b. Remove guide bushing (12).
b. Pour oil into a suitable container.
C. Remove seal spacer (13).
Complete Disassembly
d. Discard oil seal (14).
NOTE
Damper and spring assembly do not need to be taken apart e. Remove stopper ring (15).
unless a component requires replacement.
f. Remove dust seal (16).
1. See Figure 3-68. Remove damper and spring assembly.
Clean and Inspect
NOTE
Have a suitable container ready to place components into 1. See Figure 3-68. Clean all parts.
after removal from tube.
2. Inspect parts for wear or damage. Replace parts as
a. Remove screw (19). Use an air impact wrench for necessary.
best results.
3. Inspect OD of slider bushing (11) and ID of guide bushing
b. Re-install longer 6mm screw approximately 4 turns. (12).
c. Tap end of screw to dislodge damper O-rings from a. If coating is worn through (metallic substrate
their bore. showing), replace bushing.
d. Remove long screw. b. Inspect for distortion.
e. Remove damper (7) and spring (6) from fork tube c. If deep scratches or scoring are found, replace
(10). bushing. Also inspect mating components for similar
wear. Replace or repair as necessary.
f. Discard damper O-rings (8 and 9).
4. Check fork tube (10) and slider (17) for scoring, scratches
g. Position damper upright to drain oil. and abnormal wear.
2. Compress spring to relieve tension on fork cap.
94000784 3-59
5. Inspect fork slider for nicks from stones and road debris, d. Seat dust seal (16) with installer.
especially in area where seal contacts it. Replace if
necessary. 3. Install spring (6) onto damper (7).
6. See Figure 3-67. Check runout with a dial indicator. 4. Install spring collar (5).
a. Set fork slider on V-blocks. 5. Using front fork compressor, compress spring to allow
access to damper rod hole.
b. Replace fork if runout exceeds:
Special Tool: FRONT FORK COMPRESSOR (HD-45966)
0.008 in (0.2 mm)
6. Connect fork tube cap.
sm02901
a. Install new O-ring (4) on fork tube cap (1).
b. Install fork tube cap on damper (7).
c. Apply thread locker to screws (2)
LOCT ITE 243 MEDIUM STRENGTH
T HREADLOCKER AND SEALANT (BLUE)
(99642-97)
Figure 3-67. Measure Fork Tube Runout d. Install one of the screws (2).
e. Install pin (3).
Initial Assembly
NOTE f. Install second screw (2). Tighten both screws.
Lubricate all seal lips and O-rings with seal grease during Torque: 53-71 in-lbs (6-8 N·m) Fork pin retaining
assembly. HARL EY-DAVIDSON SEAL GREASE (11300005) screw, left, Smodels
7. Remove front fork compressor.
1. See Figure 3-68. Assemble fork slider.
8. Install damper and spring assembly.
a. Install dust seal (16).
b. Install stopper ring (15). a. Install new O-rings (8 and 9) on damper (7).
c. Install new oil seal (14) with lettering facing down. b. Install damper into fork tube (10).
d. Install seal spacer (13). c. Install new screw (19). Tighten.
Torque: 133-221 in-lbs (15-25 N·m) Fork tube
e. Install guide bushing (12). damper screw, left, Smodels
f. Install slider bushing (11). Expand bushing only Fork Fill
enough to fit fork slider (17).
1. See Figure 3-68. Remove fork tube cap (1).
2. Assemble fork slider to fork tube.
NOTE 2. Fill fork with fork oil.
Install spring tapered end up. Volume: 17.4 fl oz (515 ml)
Consumable: T YPE "D" HYDRAULIC FORK OIL
(62600098)
a. Slide fork slider (17) into fork tube (10).
3. Install fork tube cap (1). Tighten.
b. Seat oil seal (14) with installer.
Torque: 22-30 ft-lbs (3�0 N·m) Fork tube cap, left side,
Special Tool: FORK SEAL DRIVER AND DUST
Smodels
BOOT INSTALLER (47MM) (8-48867)
Special Tool: FORK CAP WRENCH (HD-50084-A)
c. Install stopper ring (15) into groove in fork tube.
4. Stroke fork assembly several times to fill and bleed air out
of damper.
1466358
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1. Fork tube cap 11. Slider bushing
2. Screw (2) 12. Guide bushing
3. Pin 13. Seal spacer
4. O-ring 14. Oil seal
5. Spring collar 15. Stopper ring
6. Spring 16. Dust seal
7. Damper 17. Fork slider
8. O-ring 18. Solenoid, damper
9. O-ring 19. Screw
10. Fork tube
Figure 3-68. Left Side Fork (S models)
--------=-
r--1-617-29-2--------.=, -==.--;;;;;;,-----, DISASSEMBLE AND ASSEMBLE: RIGHT
SIDE. S MODELS. WITHOUT ARH
PART NUMBER TOOL NAME
8-48867 FORK SEAL DRIVER AND DUST BOOT
I N STALLER (47MM)
HD-41177 FORK TUBE HOLDER
HD-50084-A FORK CAP WRENCH
HD-53046 INNER FORK NUT SOCKET
FASTENER TORQUE VALUE
Fork piston rod hex nut, right 13-17 fl-lbs 17.5-22.5 N·m
side
Fork tube cap, right side 22-30 fl-lbs 30--40 N·m
Joint rod collar, right side, S 69-83 fl-lbs 93-113 N·m
without ARH
CONSUMABLE PART NUMBER
HARLEY-DAVIDSON 11300005
SEAL GREASE
T Y PE "D" 62600098
Figure 3-69. Front Fork Screws (do not remove) HYDRAULIC FORK
OI L
94000784 3-61
Disassemble Drain Fork Oil
Initial Disassembly 1. Drain fork oil.
1. See Figure 3-70. Clamp fork tube in fork tube holder. Mount a. Partially compress fork.
in vise with fork vertical.
Special Tool: FORK T UBE HOLDER (HD-41177) b. Pour oil into a suitable container
A WARNING Complete Disassembly
Wear safety glasses or goggles when servicing fork 1. See Figure 3-72. Separate fork tube from fork slider..
assembly. Do not remove slider tube caps without relieving
spring preload or caps and springs can fly out, which could
a. Remove dust seal (13).
result in death or serious injury. (00297a)
b. Remove stopper ring (12) from groove inside fork
2. See Figure 3-72. Use fork cap wrench to remove fork tube tube (7).
cap (1 ).
c. Expand fork slider (14) and fork tube against each
Special Tool: FORK CAP WRENCH (HD-50084-A)
other repeatedly (in a slide-hammer effect) to remove
3. Relocate fork tube holder and clamp fork slider. fork tube.
NOTE 2. Disassemble fork slider.
Have a suitable container ready to place components into
after removal from tube.
a. Remove slider bushing (8).
4. Remove joint rod. b. Remove guide bushing (9).
a. Raise fork tube cap above fork tube (7). C. Remove seal spacer (10).
b. Separate nut (3) from fork tube cap. d. Discard oil seal (11 ).
c. Remove joint rod (5) from fork tube cap. e. Remove stopper ring (12).
d. Use inner fork nut socket to remove joint rod collar f. Remove dust seal (13).
(4).
Special Tool: INNER FORK NUT SOCKET Clean and Inspect
(HD-53046)
1. Clean all parts.
e. Remove joint rod (5) and spring.
2. Inspect parts for wear or damage. Replace parts as
5. Discard O-ring (2). necessary.
6. Remove spring (6). 3. Inspect OD of slider bushing and ID of fork tube bushing.
a. If coating is worn through (metallic substrate
1096076
showing), replace bushing.
b. Inspect for distortion.
c. If deep scratches or scoring are found, replace
bushing. Also inspect mating components for similar
wear. Replace or repair as necessary.
4. Check fork tube and slider for scoring, scratches and
abnormal wear.
5. Inspect fork tube for nicks from stones and road debris,
especially in area where seal contacts it. Replace if
necessary.
6. See Figure 3-71. Check runout with a dial indicator.
1. Fork tube holder
2. Fork tube a. Set fork slider on V-blocks.
Figure 3-70. Fork Tube Holder
b. Replace fork if runout exceeds:
0.008 in (0.2 mm) Assemble For Fork Fill
1. Mount fork assembly in fork tube holder and fully compress
sm02901
assembly.
Special Tool: FORK TUBE HOLDER (HD-41177)
NOTE
Install spring tapered end up.
2. See Figure 3-72. Install spring (6).
3. Install joint rod (5) and spring.
Figure 3-71. Measure Fork Tube Runout 4. Install joint rod collar.
Initial Assembly a. Install joint rod collar (4) in fork tube (7).
1. NOTE b. Using inner fork nut socket, tighten joint rod collar.
Lubricate all seal lips and O-rings with seal grease during
Torque: 69--83 ft-lbs (93--113 N·m) Joint rod collar,
assembly. HARLEY-DAVIDSON SEAL GREASE
right side, S without ARH
(11300005)
Special Tool: INNER FORK NUT SOCKET
(HD-53046)
See Figure 3-72. Assemble fork slider.
Fork Fill
a. Install dust seal (13).
1. Mount fork assembly in fork tube holder.
b. Install stopper ring (12).
Special Tool: FORK TUBE HOLDER (HD-41177)
c. Install new oil seal (11) with lettering facing down. 2. Fill fork with fork oil.
d. Install seal spacer (10). Volume: 22 fl oz (650 ml)
Consumable: TYPE "D" HYDRAULIC FORK OIL
e. Install guide bushing (9). (62600098)
f. Expand slider bushing (8) only enough to fit fork Complete Assembly
slider (14). Install slider bushing.
1. See Figure 3-72. Install fork tube cap on joint rod assembly.
2. Assemble fork slider to fork tube.
a. Install new a-ring (2) on fork tube cap (1).
a. Slide fork slider into fork tube (7).
b. Fully install fork tube cap.
b. Seat oil seal with installer. c. Tighten nut (3) against fork tube cap.
Special Tool: FORK SEAL DRIVER AND DUST Torque: 13--17 ft-lbs (17.5--22.5 N·m) Fork piston
BOOT IN STALLER (47MM) (B-48867) rod hex nut, right side
c. Install stopper ring (12) into groove in fork tube.
2. Relocate fork tube holder to clamp fork tube (7).
d. Seat dust seal (13) with installer.
3. Install fork tube cap (1). Tighten.
Torque: 22-30 ft-lbs (30--40 N·m) Fork tube cap, right side
Special Tool: FORK CAP WRENCH (HD-50084-A)
94000784 3-63
1466362
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1. Fork tube cap 8. Slider bushing
2. O-ring 9. Guide bushing
3. Nut 10. Seal spacer
4. Joint rod collar 11. Oil seal
5. Joint rod 12. Stopper ring
6. Spring 13. Dust seal
7. Fork tube 14. Fork slider
Figure 3-72. Right Side Fork (5 models without ARH)
DISASSEMBLE AND ASSEMBLE: RIGHT Disassemble
SIDE. S MODELS. WITH ARH
Initial Disassembly
PART NUMBER TOOLNAME
1. See Figure 3-73. Clamp fork tube in fork tube holder. Mount
8-41177 FORK HOLDING TOOL in vise with fork vertical.
8-48867 FORK SEAL DRIVER AND DUST BOOT
Special Tool: FORK TUBE HOLDER (HD-41177)
INSTALLER (47MM)
NOTE
HD-41177 FORK TUBE HOLDER
Have a suitable container ready to place components into
HD-53115 ADAPTIVE RIDE HEIGHT FORK CAP after removal from tube.
SOCKET
FASTENER TORQUE VALUE 2. See Figure 3-75. Loosen damper.
Fork damper, right side 22-30 fl-lbs 30-40 N·m
a. Remove screws (1).
Fork tube damper screw, right, 133-221 in-lbs 15--25 N·m
S models
b. Use a drop of fork oil to lubricate cap wire seals.
Fork tube cap screw, right side 6-8 in-lbs 0.7-0.9 N·m
ARH c. Lift cap (2).
CONSUMABLE PART NUMBER d. Use adaptive ride height fork cap socket to loosen
HARLEY-DAVIDSON 11300005 damper (3) and spring assembly.
SEAL GREASE Special Tool: ADAPTIVE RIDE HEIGHT FORK CAP
TYPE "D" 62600098 SOCKET (HD-53115)
HYDRAULIC FORK
OIL 3. Remove fork from fork tube holder.
3-64 94000784
i. Remove spring (5).
1096076
j. Remove 6mm screw from damper rod.
4. See Figure 3-76. Drain oil from damper.
a. Press check ball (2) using a wooden dowel or
appropriate tool.
b. Pump damper rod.
c. Pull out on damper rod jack (1) to drain remaining
oil.
5. Separate fork tube from fork slider.
a. Remove dust seal (15).
1. Fork tube holder
b. Remove stopper ring (14) from groove inside fork
2. Fork tube
tube (9).
Figure 3-73. Fork Tube Holder
c. Expand fork slider (16) and fork tube against each
Drain Fork Oil other repeatedly (in a slide-hammer effect) to remove
fork tube.
1. Drain fork oil.
6. Disassemble fork slider.
a. Partially compress fork.
NOTE
b. Pour oil into a suitable container See Figure 3-77. Screw in front fork axle housing are not
serviceable and should not be removed.
Complete Disassembly
a. See Figure 3-75. Remove slider bushing (10).
NOTE
Have a suitable container ready to place components into after b. Remove guide bushing (11).
removal from tube.
c. Remove seal spacer (12).
1. See Figure 3-75. Remove damper and spring assembly.
d. Discard oil seal (13).
a. Remove screw (17). Use an air impact wrench for Remove stopper ring (14).
e.
best results.
f. Remove dust seal (15).
b. Remove damper (3) and spring assembly from fork
tube (9).
Clean and Inspect
2. Discard o-ring (4). 1. Clean all parts.
3. Remove spring from damper. 2. Inspect parts for wear or damage. Replace parts as
necessary.
a. Using a longer 6mm screw, install screw
approximately 4 turns into damper rod. 3. Inspect OD of slider bushing and ID of fork tube bushing.
b. Secure screw head in vise.
a. If coating is worn through (metallic substrate
c. Compress spring slightly by pulling spring joint (7) showing), replace bushing.
away from vise.
b. Inspect for distortion.
d. Remove stopper ring (8) from groove.
c. If deep scratches or scoring are found, replace
bushing. Also inspect mating components for similar
e. Remove screw head from vise.
wear. Replace or repair as necessary.
f. Remove stopper ring.
4. Check fork tube and slider for scoring, scratches and
g. Remove spring joint. abnormal wear.
h. Remove washer (6).
5. Inspect fork tube for nicks from stones and road debris, b. Turn ignition switch ON.
especially in area where seal contacts it. Replace if
necessary. c. Retract damper rod jack.
6. See Figure 3-74. Check runout with a dial indicator. d. Turn ignition switch OFF.
e. Disconnect the damper assembly electrical
a. Set fork slider on V-blocks. connector.
b. Replace fork if runout exceeds:
4. See Figure 3-75. Install spring (5) on damper (3).
0.008 in (0.2 mm)
a. Install washer (6).
sm02901
b. Install spring joint (7).
c. Install stopper ring (8).
d. Use long 6mm screw 4 turns into damper rod.
e. Clamp screw head in vise.
f. Compress spring slightly by pulling spring joint (7)
away from vise.
Figure 3-74. Measure Fork Tube Runout
g. Install stopper ring (8) into groove.
Initial Assembly
h. Remove screw head from vise.
NOTE
Lubricate all seal lips and O-rings with seal grease during i. Remove 6mm screw from damper rod.
assembly. HARLEY-DAVIDSON SEAL GREASE (11300005)
5. Install new O-ring (4) on damper.
1. See Figure 3-75. Assemble fork slider.
6. Install damper and spring assembly.
a. Install dust seal (15).
a. Install damper (3) and spring into fork tube.
b. Install stopper ring (14).
b. Install screw (17). Tighten.
c. Install new oil seal (13) with lettering facing down. Torque: 133-221 in-lbs (15-25 N·m) Fork tube
damper screw, right, S models
d. Install seal spacer (12).
Fork Fill
e. Install guide bushing (11).
1. Mount fork assembly in fork tube holder
f. Install slider bushing (10). Expand bushing only
enough to fit fork slider (16). Special Tool: FORK HOLDING TOOL (B-41177)
2. Fill fork with fork oil.
2. Assemble fork slider to fork tube.
Volume: 14 fl oz (417 ml)
NOTE Consumable: TYPE "D" HYDRAULIC FORK OIL
Install spring tapered end up. (62600098)
a. Slide fork slider into fork tube. Complete Assembly
1. See Figure 3-75. Install fork damper on fork tube assembly.
b. Seat oil seal with installer.
Special Tool: FORK SEAL DRIVER AND DUST a. Install damper (3) into fork tube. Tighten.
BOOT INSTALLER (47MM) (B-48867)
Torque: 22-30 ft-lbs (30-40 N·m) Fork damper, right
c. Install stopper ring (14) into groove in fork tube. side
d. Seat dust seal with installer. b. Slide fork tube cap (2) down wires into position.
C. Install screws (1). T ighten.
3. Retract damper rod jack back to original position.
Torque: 6-8 in-lbs (0.7-0.9 N·m) Fork tube cap
a. Connect the damper assembly electrical connector. screw, right side ARH
2. Remove fork from fork tube holder.
3-66 94000784
\
\ I
\
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1. Screw (4) 10. Slider bushing
2. Cap 11. Guide bushing
3. Damper 12. Seal spacer
4. 0-ring 13. Oil seal
5. Spring 14. Stopper ring
6. Washer 15. Dust seal
7. Spring joint 16. Fork slider
8. Stopper ring 17. Screw
9. Fork tube
Figure 3-75. Right Side Fork (S models with ARH)
�-----------,
1. Damper rod jack
2. Check valve
Figure 3-76. Damper Rod Check Valve
94000784 3-67
1617765
COMPLETE
1. Install front wheel. See FRONT WHEEL (Page 3-8).
2. Attach front brake calipers. See FRONT BRAKE CALIPER
(Page 3-32).
3. Install front fender. See FRONT FENDER (Page 3-102).
4. Lower front wheel. See Secure the Motorcycle for Service
in GENERAL (Page 2-2).
5. Install fairing. See FAIRING (Page 3-89).
Figure 3-77. Front Fork Screw (do not remove)