Softail Rear Lowering Kit Instruction Sheet - Harley
Contents
1. 12 Repeat for the second shock absorber NOTE The second shock absorber must be assembled with the keeper plate and the jam nut exposing an identical number of threads on the stub shaft is05843a Jam nut Keeper plate Stub Shaft Shock threads add Loctite Shock shaft nut Adjuster collar facing frame bracket Shock spacer Cotter pin Shock absorber spring 10 Retaining ring 11 Spring seat Figure 2 Shock Absorber to Stub Shaft Assembly PONOnPena is04139 1 Spanner wrench 2 Keeper plate Figure 3 Spanner Wrench Part Number HD 94455 89 J03392 Install the Shock 1 Slide the bushing over the stub shaft and insert the shaft through the frame bracket 2 Slip a rubber grommet and cup washer onto the shock absorber shaft and loosely fasten with the flanged locknut Check that the washer grommet assemblies properly fit the hole in the frame bracket Do not tighten at this time 3 Insert a new cotter pin through the hole in the end of the shock stub shaft and spread the pin 4 Align the shock absorber eye with the rear fork mount by adjusting the rear wheel height with the screw jack 5 Fasten the shock absorber to the rear fork with the stock washer and bolt as follows a Apply LOCTITE 243 blue to the bolt threads b Apply Anti Seize Lubricant Harley Davidson Part Number 98960 97 to the bolt shoulder c Thread the bolt through the shock absorber eye and2. into the rear fork mount but do not tighten 6 Repeat for the second shock absorber NOTE The number of exposed threads on the stub shafts must be equal between the two shock absorbers 7 With the screw jack raise or lower the rear wheel to the desired ride height Set both shock absorbers to exactly the same ride height as follows a Snug the flanged locknut down to the cup washers b Count the number of threads showing on the shaft in front of the flanged locknut c Turn the shock side adjuster collar up to capture the cup washers rubber grommet and bushings against the bracket Continue to raise or lower the rear wheel and turning the adjuster collar to precisely set the ride height NOTE Snap on Tool Co adapter Part Number SRES 24 is required to gain access to the shock absorber bolts When adding an adapter or extension to a torque wrench bolt torque must be computed A Torque Computer Part Number SS 306G is available from Snap on Tool Co The computer is easy to use with dial or click type torque wrenches 8 Tighten each rear shock mounting bolt to 115 130 ft lbs 156 176 Nm 9 Tighten each flanged locknut to 32 39 ft lbs 43 4 52 9 Nm Return the Motorcycle to Service 1 Remove the screw jack from under the rear wheel Lower the rear of the motorcycle back down with the crane or hoist then free the motorcycle from the lifting and securing devices 2 Connect the negative battery cable to
3. cMOTOR HARLEY DAVIDSON WY J03392 INSTRUCTIONS REV 2009 02 13 SOFTAIL REAR LOWERING KIT GENERAL Kit Number 54001 04A Models For model fitment information see the P amp A Retail Catalog or the Parts and Accessories section of www harley davidson com English only Additional Parts Required To access the shock absorber bolts a Snap on Tool Co adapter Part Number SRES 24 is required To adjust the preload Harley Davidson Shock Absorber Spanner Wrench Part number HD 94455 89 is required LOCTITE 243 blue Harley Davidson Part Number 99642 97 and Anti Seize Lubricant Harley Davidson Part Number 98960 97 are required for this installation and can be pur chased at a Harley Davidson dealer WARNING The rider s safety depends upon the correct installation of this kit If the procedure is not within your capabilities or you do not have the correct tools have a Harley Dav idson dealer perform the installation Improper installation of this kit could result in death or serious injury 00308a NOTE This instruction sheet references Service Manual information A Service Manual for your model motorcycle is required for this installation and is available from a Harley Davidson Dealer WARNING Installation of any accessory suspension components can affect cornering clearance This could distract the rider causing loss of control and death or serious injury 00431b NOTE Rear shock abs
4. d the shaft off the a Holding the inner shock assembly with the shock shaft shock down first install the spring seat 11 with its chamfer 8 Thread off the jam nut from the existing stub shaft facing the retaining clip then slide on the shock spacer 7 from the kit Assemble the Shock and Lowering Kit b Carefully insert the inner shock assembly into the 1 See Figure 2 Thread the jam nut 1 and the keeper plate outer canister 2 on the stub shaft 3 from the kit f 7 Inthe press as before support the fork end of the spring a ee T E P etl Pal Numoer shock assembly and compress the stub shaft 3 until the pip shocksna gaca d keeper plate travels below the retaining ring notch in the 3 Holding the flats 5 on the shock shaft nut tighten the bore of the shock canister new stub shaft down fully on the shock shaft threads 8 Snap the retaining ring 10 into place a he oe Si t p a a F K T SES 9 Carefully release the press until the spring pushes the aP JUSIMETT SRI TONE PATR OM TIES TOCS Naik keeper plate firmly against the retainer ring and remove NOTE the spring shock assembly from the press This is the MINIMUM preload position Preload can be adjusted 10 See Figure 2 Thread on an adjuster collar 6 from the kit after installation for operating load 5 Snug the jam nut down on the keeper plate J03392 Ti with the flange facing the frame bracket Slip a cup washer and a rubber grommet over the shaft 2of4
5. frame bracket 4 and remove the shock absorber w Remove inspect and if necessary replace the rubber grommets the cup washers 5 and the bushing 3 4 Repeat for the other shock absorber Disassemble the Shock k Thoroughly clean the rear fork end of the shock especially near the shock canister seal 2 Support the rear fork end of the shock absorber and shock canister on the table of a press 3 Press on the shaft to compress the spring in the canister until the keeper plate drops down away from the retaining ring WARNING Wear safety glasses or goggles when removing or installing retaining rings Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury 00312a 1 of 4 Please dispose of materials responsibly 4 Use a mechanics pick to remove the ring 6 Carefully remove the inner shock assembly and spring 5 Carefully rel th d te th t seat from the outer cannister Do not remove the clip from i Rei eg GaSe ME press And Separate Mepars the damper body that retains the seat Do not remove the spring or nylon washers from the shock canister is04137 1 Bolt and washer 2 Shock absorber 3 Bushing 4 Frame bracket 5 Cup washer with grommet 6 Flanged locknut Figure 1 Softail Rear Suspension 7 Holding the flats on the shock shaft nut use a wrenchon 6 See Figure 2 Assemble the shock absorber flats of the existing stub shaft and threa
6. ise the height Turn the adjuster collar IN towards the shock end of the stub shaft To decrease rear wheel travel and lower ride height Turn the adjuster collar OUT towards the frame bracket NOTES Longer shock length from the frame bracket to the shock eye will equal lower motorcycle ride height With this kit ride height is adjustable from 0 5 to 1 0 in 12 7 to 25 4 mm Each com plete revolution of the flanged nut equals approximately 0 140 in 3 55 mm of ride height Adjust ride height according to rider preference However when operating under heavy loads the lowest ride height set ting with the minimum preload setting may cause the rear tire to contact the rear fender 3 When the desired ride height has been reached tighten the flanged locknut on the front of the frame bracket to 32 39 ft lbs 43 4 52 9 Nm 4 Repeat for the opposite shock NOTE Equal settings are required on both shock absorbers to maintain handling SERVICE PARTS 7 KO C amp _ Ca Q Figure 4 Service Parts Softail Rear Lowering Kit Table 1 Service Parts Table Item Description Quantity Part Number 1 Cotter pin 2 520W Adjuster collar 2 Not Sold Separately Stub shaft 2 Not Sold Separately AJOJN Shock spacer 2 11892 J03392 4of4
7. orbers on Softail models cannot be repaired If a shock absorber becomes damaged it must be replaced Kit Contents See Figure 4 and Table 1 INSTALLATION Prepare the Motorcycle 1 Follow the Service Manual instructions to remove the seat J03392 amp Many Harley Davidson Parts amp Accessories are made of plastics and metals which can be recycled WARNING To prevent accidental vehicle start up which could cause death or serious injury disconnect negative battery cable before proceeding 00048a 2 Disconnect the negative battery cable from the battery 3 Place motorcycle on a lift and secure the front wheel 4 Use an overhead crane or hoist attached to the frame to lift the rear of the motorcycle to allow the rear fork to pivot through its range of travel a Place a screw jack under the rear wheel to support and adjust the rear fork during shock removal installation and ride height adjustment WARNING Be sure rear wheel is supported when removing rear shocks If wheel is not supported rear fork can drop down which could result in death or serious injury 00481b Removal 1 See Figure 1 Remove the bolt and washer 1 that fasten each of the shock absorbers 2 to the rear fork NOTE Snap on Tool Co adapter Part Number SRES 24 is necessary to gain access to the shock absorber bolts 2 Remove the flanged locknut 6 and cup washer with grommet 5 fastening the shock absorber to the
8. the battery 3 of 4 IWIN NIN After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b 3 Install the seat 4 After operating the motorcycle adjust the suspension as desired for preload and ride height SUSPENSION ADJUSTMENTS Preload NOTE Adjust spring compression to compensate for motorcycle load 1 Place a mark in the same position on the keeper plate of each shock 2 Loosen the jam nut on each shock 3 See Figure 3 Use the shock absorber spanner wrench 1 Part Number HD 94455 89 to rotate each keeper plate 2 to release or compress the springs For heavier loads Turn the keeper plates OUT counter clockwise toward the jam nut to increase spring preload For lighter loads Turn the keeper plates IN clockwise away from the jam nut to decrease spring preload 4 Adjust both shock absorbers equally the same number of turns and to the same position relative to the marks 5 Tighten the jam nut against each of the shock absorber keeper plates Ride Height NOTE Ride height is adjusted with the motorcycle suspended and a screw jack under the rear wheel to raise lower the suspension 1 Loosen the flanged locknut on the front of the frame bracket 2 Turn the adjuster collar in the direction of the desired ride height To increase rear wheel travel and ra
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