Harley Davidson FLH/FLT/FXR Evolution service manual
Contents
1. 581 3 Check the internal threads in the top of the fork tube Figure 51 for stripping cross threading or sealer resi due Use a tap to true the threads and to remove sealer de posits 4 Check the fork tube plug O ring A Figure 52 for hardness or deterioration Replace if necessary 5 Check the external threads on the fork tube plug B Figure 52 for stripping cross threading or sealer resi due Use a die to true the threads and to remove sealer de posits 6 Make sure the oil passage hole in the fork tube Figure 53 is open If it is clogged flush it with solvent and dry it with compressed air 7 Check the fork cap bolt O ring A Figure 54 for hardness or deterioration Replace if necessary 8 Check the external threads on the fork cap B Figure 54 for stripping cross threading or sealer residue Use a die to true the threads and to remove sealer deposits 9 Check the slider Figure 55 for dents or other exterior damage Check the retaining ring groove Figure 56 in the top of the slider for cracks or other damage 10 Check the front caliper mounting bosses for cracks or damage 11 Check the threaded studs A Figure 57 on the base of the slider for thread damage Repair if necessary 12 Check the drain screw B Figure 57 and washer for damage 13 Check the slider A Figure 58 and fork tube bush ings B for excessive wear cracks or damage 14 Remove the fork tube bushing as follows a Expand the b2. chapter Position the handlebar so that the control cables are not kinked or damaged 4 Remove the front fork as described in this chapter 5 Remove the brake hose bracket at the bottom of the fork stem bracket Do not disconnect the brake hose con nection CAUTION Secure the steering stem before removing the fork stem nut in the following steps or it will fall to the ground 6 Loosen and remove the steering stem nut 7 Loosen the upper bracket pinch bolt 8 Remove the upper bracket from the steering stem 9 Lower the fork stem out of the steering head 10 Remove the upper dust shield 11 Remove the bearing from the upper bearing race in the steering head cup 12 Inspect the fork stem assembly as described later in this chapter Installation 1 Thoroughly pack both bearings with bearing grease 2 Make sure the steering head and stem races are prop erly seated 3 Apply alight coat of grease to the steering head races 4 Install the lower dust shield onto the lower bearing on the steering stem 5 Install the steering stem into the steering head and hold it firmly in place 6 Install the upper bearing over the steering stem and seat into the upper race 7 Install the upper dust shield 594 8 Install the upper bracket over the steering stem 9 Install the steering stem nut until it is finger tight NOTE Final tightening of the steering stem nut will occur after the front wheel is installed and t
3. form Steps 1 7 under Removal All 1984 1996 FLH and FLT series models except 1984 1996 FLHT and FLHTC in this section 1B On 1986 1996 FLHTC models perform Steps 1 7 under Removal 1986 1996 FLHT and FLHTC models in this section 2A On 1984 1987 models remove the hose fitting and O ring from the bottom of the antidive solenoid 2B On 1988 1996 models remove the banjo bolt O rings and hose fitting from the bottom of the antidive solenoid 3 If so equipped remove the antidive valve cover nut 4 Remove the antidive valve case antidive valve spacer and rubber washer 5 To remove the plunger body from the antidive valve as follows a On 1984 models use a spanner wrench and un screw the plunger body from the antidive valve Ifa spanner wrench is not available thread two thin jam nuts onto the plunger body and lock them together b On 1985 and later models use a screwdriver and unscrew and remove the plunger body CHAPTER ELEVEN STEERING STEM AND BRACKET 1984 1987 FXR SERIES MODELS 1 Steering stem nut 5 Bearing race 2 Upper bracket 6 Frame steering head just shield 7 Steering stem and 4 Bearing lower bracket 6 After removing the plunger body remove the spring plunger and O ring from the plunger body 7 To ensure an air tight system install all new steel and copper washers and O rings 8 Remove all sealer residue from the plunger body and antidive valve threads 9 Install a new O ring
4. 4 Remove the antidive valve and its housing O ring and spacer 5 Unscrew the air hoses from the valve body Remove the hoses and the O rings Discard the O rings 6 Remove the plunger body from the antidive valve as follows FRONT SUSPENSION AND STEERING a On 1984 models use a spanner wrench and un screw the plunger body from the antidive valve Ifa spanner wrench is not available thread two thin jam nuts onto the plunger body and lock them together b On 1985 and later models use a screwdriver and unscrew and remove the plunger body 7 After removing the plunger body remove the spring plunger and O ring from the plunger body 8 To ensure an air tight system replace all steel and cop per washers and O rings 9 Remove all sealer residue from the plunger body and antidive valve threads 10 Install a new O ring into the air manifold recess 11 Position the smaller outer diameter of the plunger spring going in first and install the spring onto the plunger 12 Coat the plunger body threads with Loctite Pipe Seal ant with Teflon and thread the plunger body into the air manifold Tighten the plunger body using the same tool and method used for removal See Step 6 13 Install the spacer washer antidive valve and valve housing 14 On early models only install the nut onto the end of the plunger body 15A On 1984 1985 models perform the following 589 a Install the nut washer and O ring onto the hose f
5. and out strokes Figure 31 Doing so will withdraw the bushing and the oil seal from the slider 576 20 Remove the slider from the fork tube If still in place remove the oil lock piece from the damper rod 21 Loosen the pinch bolt Figure 32 Slide the fork tube out of the lower fork bracket and remove the rubber stop Figure 29 from the fork tube It might be necessary to rotate the fork tube slightly while pulling it down and out Remove the fork assembly and take it to the 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 22 Repeat for the other fork assembly Installation Fork Was Serviced 1 Assemble the fork as described in this chapter 2 Install a fork tube through the lower fork bracket and install the rubber fork stop Figure 29 3 Continue to push the fork tube up through the top fork bracket until it bottoms against the upper fork bracket 4 Tighten the pinch bolt Figure 32 to 40 ft lb 54 Nem 5 Install the fork cap bolt Figure 27 onto the top of the fork tube and tighten securely 6 Install new O rings onto all the hex bolts Figure 30 and apply a light coat of clean engine oil to them 7 Install the air tube assembly onto the top of the fork as semblies and install the hex bolts through the banjo bolts Tighten the hex bolts to 97 142 in Ib 11 16 Nem 8 On models so equipped install the right saddl
6. moving the upper fork bracket pinch bolt in Step 11 12 Loosen and remove the bearing adjust nut then slide the steering stem and bracket out of the steering head 13 Remove the upper dust shield from the steering head PNMASHONs STEERING STEM AND BRACKET FXSB AND FXEF MODELS Steering stem nut Bolt Upper bracket Insert Screw Dust shield Bearing Bearing race CHAPTER ELEVEN Bearing cup Frame steering head Cover Screw Steering stem and lower bracket Bolt FRONT SUSPENSION AND STEERING STEERING STEM AND BRACKET FLH AND FLT SERIES MODELS Steering stem nut Upper fork bracket Bearing adjust nut Upper dust shield Bearing 6 Bearing race 7 Bearing race 8 Bearing and lower dust shield 9 Steering stem 14 Remove the bearing from the upper bearing race in the steering head 15 Inspect the steering stem assembly as described in this section Installation 1 Thoroughly pack both bearings with bearing grease 2 Make sure the steering head and stem races are prop erly seated 3 Apply a light coat of grease to the steering head races 595 4 Install the lower dust shield onto the lower bearing on the steering stem 5 Install the steering stem into the steering head and hold it firmly in place 6 Install the upper bearing over the steering stem and seat it into the upper race 7 Install the upper dust shield 8 Install the
7. steering head and hold it firmly in place 6 Install the upper bearing over the fork stem and seat into the upper race 7 Install the upper dust shield 8 Install the upper bracket onto the steering stem and tighten the steering stem pinch bolt securely 9 Install the fork stem nut on early models or the steering stem bolt on later models Tighten securely 10 Install the front fork as described in this chapter 11 Tighten the upper bracket to fork stem pinch bolt to the specification in Table 5 CAUTION Do not overtighten the fork stem nut or bolt in Step 12 or the bearings and races can be damaged 12 Tighten the fork stem nut or bolt to remove all notice able play in the fork stem 13 Install the handlebar assembly as described in this chapter 14 Install the fuel tank as described in Chapter Nine 15 Adjust the front steering as described in this chapter 16 On models with the air control system install the air control system onto the upper fork bracket as described in this chapter FXWG Models Removal Refer to Figure 74 1 Remove the front wheel as described in Chapter Ten 2 Remove the fuel tank as described in Chapter Nine 3 Remove the handlebar assembly as described in this chapter Position the handlebar so that the control cables are not kinked or damaged 4 Remove the front fork as described in this chapter 5 Remove the headlight and headlight bracket as de scribed in Chapter Nine 1
8. tube assemblies are going to be removed mark them with an R right side and L left side so the as semblies will be reinstalled on the correct sides 7 On models so equipped remove the right saddlebag as described in Chapter Fifteen WARNING Use caution when releasing the air from the front fork air valve Moisture and fork oil may spurt out when the air pressure is re leased Protect eyes accordingly 8 Cover the rear brake assembly and wheel prior to re leasing the compressed air from the rear air valve If nec essary wipe any oil reside that may have been ejected from the air valve 9 Remove the cap from the front fork air valve Figure 24 Then slowly depress the air valve to evacuate the air from the front fork air pipe system Unscrew and remove the core from the air valve Place the air valve core and cap in a reclosable plastic bag to avoid misplacing them 10 Refer to Figure 25 Unscrew and remove the hex bolts Figure 26 securing the banjo bolt on top of each fork tube Move the air tube assembly out of the way from the fork assemblies 574 CHAPTER ELEVEN 11 Remove the fork cap bolt Figure 27 from the top of the fork tube 12 Working at the base of the steering stem loosen the pinch bolt Figure 28 13 Slide the fork tube out of the upper fork bracket Re move the rubber stop Figure 29 from the fork tube 14 Continue to slide the fork tube out of the lower fork bracket It may be necessa
9. 1 27 28 37 1987 FXLR FXRS and 1988 1992 FXR 25 30 34 41 1993 1994 FXR 30 35 41 47 FXWG FXR2 and FXR3 Fork stem nut 35 40 47 54 Brake hose to lower steering stem bracket 133 15 FXSB and FXEF Fork stem nut See text Upper bracket to fork stem pinch bolt 20 25 gt 27 34 FLH and FLT series models Fork stem nut 35 40 47 54 Steering stem nut FLH and FLT 35 40 41 54
10. 2 3 4 5 6 7 8 CHAPTER ELEVEN STEERING STEM AND BRACKET FXWG MODELS Cap Steering stem nut Lockwasher Upper bracket Adjust nut Upper dust shield Bearing Bearing race Bearing cup Frame steering head Lower dust shield Steering stem and lower bracket Washer Bolt FRONT SUSPENSION AND STEERING 6 Remove the brake hose bracket at the bottom of the fork stem bracket Do not disconnect the brake hose con nection 7 Disconnect the ground wire at the fork stem bracket 8 Remove the steering stem cap from the fork stem nut 9 Straighten the lockwasher tab away from the steering stem nut Then loosen and remove the nut and lock washer 10 Remove the upper steering stem bracket from the steering stem NOTE To prevent the steering stem from falling out hold onto the steering stem when re moving the upper fork bracket pinch bolt in Step 11 11 Loosen and remove the bearing adjust nut Then slide the steering stem and bracket out of the steering head 12 Remove the upper dust shield from the steering head 13 Remove the bearing from the upper bearing race in the steering head 14 Inspect the fork stem assembly as described in this section Installation 1 Thoroughly pack both bearings with bearing grease 2 Make sure the steering head and stem races are prop erly seated 3 Apply a light coat of grease to the steering head races 4 Install the low
11. 3 or Table 4 FRONT SUSPENSION AND STEERING Air valve 4 Increase or decrease air pressure to achieve the desired ride and control 5 Install the air valve cap System Inspection All models except 1996 1998 FLH and FLT series Refer to Figures 64 66 1 Check the tightness of the valve core within the air valve If the valve core is tight fill the system once again 583 and put some soapy water on the valve If air bubbles appear across the face of the valve the valve might be damaged If air is not leaking from the valve core se curely tighten all of the air line fittings and recheck 2 Visually inspect the air lines for cracks or other signs of damage If tightening the fittings does not stop the leak remove the assembly and replace worn or damaged parts 3 On FLH and FLT series models perform the following a Check the ground connector screwed onto the air manifold If the screws are loose air can leak out of the screw hole b If the screws are loose or suspect remove them from the ground connector and apply Loctite Pipe Sealant with Teflon to the screw threads Reinstall the screws and tighten securely c Check the system once again for leaks NOTE When removing the air control system as de scribed in this chapter you should replace all of the O rings and copper washers if used during assembly 4 Check the antidive solenoid operation as follows a Turn the ignition switch on b Apply t
12. FRONT SUSPENSION AND STEERING 573 17 If necessary on FXWG models insert a clear plastic tube into the fork cap bolt opening Figure 22 Attach a funnel to the plastic tube and refill each fork leg with the correct viscosity and quantity of fork oil in Table 1 Re move the small funnel and plastic tube Install the cap washer and oil seal FRONT FORK FLH AND FLT SERIES MODELS Before assuming a fork is malfunctioning drain the front fork oil and refill with the proper type and quantity fork oil as described in Chapter Three If there is still a problem such as poor damping a tendency to bottom or top out or leaks around the oil seals follow the service procedures in this section To simplify fork service and to prevent the mixing of parts remove service and install the fork legs individu ally Removal Fork Not To Be Serviced 1A Onall FLHT series models remove the outer fairing On FLHTC series models also remove the storage box Refer to Chapter Fifteen 1B On all FLHR series models remove the headlight na celle as described in Chapter Nine 2 Remove the passing lamp assembly as described in Chapter Nine 3 Support the motorcycle with the front wheel off the ground Refer to Motorcycle Stands in Chapter Ten 4 Remove the front fender and front wheel as described in Chapter Nine 5 Remove the screws securing the chrome mounting bracket Figure 23 and remove the bracket 6 If both fork
13. Plunger body Bracket 1985 30 O ring Bracket 1986 31 O ring 1986 Fork slider tube 32 Banjo fitting 1986 cap O ring 33 Banjo bolt 1986 2 Remove the air valve cap depress the air valve and bleed the system 3 Remove the instrument from the handlebar as de scribed in Chapter Nine 4 Remove both banjo bolts and the washers securing the air tubes to the fork cap 5 Remove the antidive valve solenoid housing bolts and washers 6 Disconnect the antidive valve electrical connectors 7 Remove the accumulator bracket bolts and washers 8 Remove the plastic tie s and clamp s securing the air hose to the fork tube 9 Remove any additional plastic ties securing the control assembly 10 Remove the air control assembly from the front fork 11 Installation is the reverse of these steps while noting the following a If removed install the air tubes to the valve body as described in this chapter Install the banjo bolts through the air tubes Make sure to place a washer on both sides of the air tube s as shown in Figure 64 Tighten the banjo bolts to 25 30 ft Ib 34 41 Nem Install the accumulator mounting bracket and the bolts Place a flat washer so it is positioned between the bolt head and the bracket Place a lockwasher so that it is positioned between the back of the bracket and the lower fork bracket Tighten these bolts to 30 35 ft Ib 41 47 Nem Slide a lockwasher onto the antidive sol
14. and front wheel 11 Adjust the front fork air pressure as described in this chapter Removal Fork To Be Serviced 1A On all FLHT models remove the outer fairing On FLHTC models also remove the storage box Refer to Chapter Fifteen 1B On all FLHR models remove the headlight nacelle as described in Chapter Nine E Banjo fitting Air tube Hex bolt 2 Remove the passing lamp assembly as described in Chapter Nine 3 Support the motorcycle with the front wheel off the ground Refer to Motorcycle Stands in Chapter Ten 4 Remove the front fender and front wheel 5 Remove the screws securing the chrome mounting bracket Figure 23 and remove the bracket FRONT SUSPENSION AND STEERING 575 6 If both fork tube assemblies are going to be removed mark them with an R right side and L left side so the as semblies will be reinstalled on the correct side 7 On models so equipped remove the right saddlebag as described in Chapter Fifteen WARNING Use caution when releasing the air from the front fork air valve Moisture and fork oil may spurt out when the air pressure is re leased Protect eyes accordingly 8 Cover the rear brake assembly and wheel prior to re leasing the compressed air from the rear air valve If nec essary wipe any oil residue that might have been ejected from the air valve 9 Remove the cap from the front fork air valve Figure 24 Then slowly depress the air val
15. bearing adjust nut and tighten to remove all bearing play 9 Install the upper bracket over the fork stem 10 Install the main circuit board and align it with the mounting bracket CAUTION Do not overtighten the fork stem nut in Step 11 or the bearings and races can be dam aged 11 Install the steering stem nut and tighten it to 35 40 ft Ib 47 54 Nem 12 On models so equipped bend the lockwasher tab against one flat on the nut If necessary tighten the nut to align it with the lockwasher 13 On 1991 1998 models pack the steering head with the same type of bearing grease originally used to pack the bearing during disassembly 14 Connect the electrical connectors from the main cir cuit board 15 Install the brake line bracket onto the lower steering stem bracket 16 Install the front fork as described in this chapter 17 On models with the air control system install the air control system from the upper fork bracket as described in this chapter 18 Install the handlebar assembly as described in this chapter 19 Install the fuel tank as described in Chapter Nine 20 On FLTC series models install the instrument panel and handlebar 21 On 1986 1998 FLHTC series models install the light bar and outer fairing as described in Chapter Fifteen 22 Install the front wheel as described in Chapter Ten 23 Adjust steering play as described in this chapter Inspection All Models The bearing outer races are
16. d Remove and discard the O rings 6 If necessary remove the antidive switch as described in this section 7 Installation is the reverse of these steps while noting the following a Install a new O ring in the bottom of the air mani fold FRONT SUSPENSION AND STEERING FRONT FORK AND REAR SHOCK ABSORBER AND AIR LINES 1997 1998 FLH AND FLT SERIES MODELS Valve cap Washer Nut Lockwasher Air line connector Bolt Bolt Front manifold and Rear manifold and air line assembly valve assembly O ring Shock absorber b Position the antidive switch on the forks if re moved and reconnect the switch electrical leads c Install the upper banjo bolts using new washers Tighten banjo bolts to 25 30 ft Ib 34 41 Nem d Reconnect the air hoses after installing all air con trol components e Pressurize the system and check for leaks 1986 1996 FLHT and FLHTC models Refer to Figure 66 1 Disconnect the negative battery cable as described in Chapter Nine NOTE Cover the fuel tank and front fender with a heavy cloth to protect them from accidental scratches or dents when removing the fol lowing components 587 2 Remove the passing lamp bracket bolts and remove the bracket from the inner fairing place the bracket onto the front fender Reinstall the lower bracket bolts into the in ner fairing to hold it in place 3 Remove the outer fairing as described in Chapter Fif teen 4 Re
17. ebag as described in Chapter Fifteen 9 Install the front fender and front wheel 10A Onall FLHT series models install the outer fairing On FLHTC series models also install the storage box Re fer to Chapter Fifteen 10B On all FLHR series models install the headlight na celle as described in Chapter Nine 11 Apply the front brake and pump the front fork several times to seat the fork tubes and front wheel cold Tiree te ee FRONT FORK FLH AND FLT SERIES MODELS 1 8 obh Fork cap bolt O ring Rubber fork stop Cover Fork tube plug O ring Spring Piston ring Damper rod Rebound spring Fork tube Stopper ring Oil seal Spacer CHAPTER ELEVEN Fork tube bushing Oil lockpiece Slider bushing Washer Drain bolt Washer Fork slider Allen bolt Lower cap Washer Lockwasher Nut right side only FRONT SUSPENSION AND STEERING 577 12 Adjust the front forks air pressure as described in this chapter Disassembly Refer to Figure 33 WARNING A special fork holding tool is required to disassemble and assemble this fork assem bly The fork spring is so strong that it can not be compressed sufficiently by hand to loosen and remove the fork tube plug This special tool is available from motorcycle dealerships 1 To protect the fork tube place a steel washer A Fig ure 34 over the fork damper rod a
18. emove the storage box Refer to Chapter Fifteen 1B Onall FLHR series models remove the headlight na celle as described in Chapter Nine 2 Remove the passing lamp assembly as described in Chapter Nine 3 Support the motorcycle with the front wheel off the ground Refer to Motorcycle Stands in Chapter Ten 4 Remove the front fender and front wheel as described in Chapter Nine 588 5 On models so equipped remove the right saddlebag as described in Chapter Fifteen WARNING Use caution when releasing the air from the front fork air valve Moisture and fork oil might spurt out when the air pressure is re leased Protect eyes accordingly 6 Cover the rear brake assembly and wheel prior to re leasing the compressed air from the rear air valve If nec essary wipe any oil residue that may have been ejected from the air valve 7 Remove the cap from the front fork air valve A Fig ure 68 Then slowly depress the air valve to evacuate the air from the front fork air pipe system Unscrew and re move the core from the air valve Place the air valve core and cap in a reclosable plastic bag to avoid misplacing them 8 Refer to Figure 69 Unscrew and remove the hex bolts Figure 70 securing the banjo bolt on top of each fork tube Move the air tube assembly out of the way of the fork assemblies 9 Remove the nut securing the air valve hose and valve mounting bracket B Figure 68 on the frame 10 Make a sketch of the front
19. enoid hous ing mounting bolts and tighten the bolts to 155 190 in Ib 17 21 Nem Reconnect the air hose Make sure to secure both ends of the hose with new hose clamps Pressurize the system as described in this chapter and check for leaks FRONT SUSPENSION AND STEERING FRONT FORK AIR CONTROL 1988 1998 FXRT FXRS SP AND FXRS CON MODELS Screw Spacer sleeve Cover FXRT Banjo bolt Spacer FXRT Washer Air manifold i Tube O ring Washer Washer Fork tube cap Rubber washer O ring Solenoid and case Fork tubes O ring Hose clamp Banjo fitting Hose Banjo bolt Hose fitting 1992 O ring 1988 1994 FXRT and FXRS SP models Refer to Figure 65 1 Disconnect the negative battery cable as described in Chapter Nine 2 Remove the air valve cap from the air valve in the left grip Depress the air valve and bleed the system 585 3 Remove the headlight as described in Chapter Nine 4 On FXRT models remove the screws securing the cover Remove the cover and the two spacers 5 On FXRS SP models remove the headlight bracket and the manifold bolts 6 Remove the banjo bolts and washers securing the air tubes to the fork caps 7 Disconnect the air hose at the antidive valve connec tion 8 Remove the air control assembly from the front fork 9 Installation is the reverse of these steps while noting the following a Position the air fork assembly into posi
20. er dust shield onto the lower bearing on the steering stem 5 Install the steering stem into the steering head and hold it firmly in place 6 Install the upper bearing over the steering stem and seat into the upper race 7 Install the upper dust shield 8 Install the bearing adjust nut and tighten to remove all bearing play 9 Install the upper bracket over the steering stem 10 Install a new lockwasher over the steering stem and insert the locating pin into the hole in the fork bracket 11 Install the steering stem nut until it is finger tight Check that the lockwasher location pin is still engaged in the hole in the upper bracket NOTE Final tightening of the steering stem nut will occur after the front wheel is installed and the front steering is adjusted as described in this section 593 12 Install the brake hose bracket to the lower steering stem bracket and tighten to 133 in Ib 15 Nem 13 Install the headlight bracket and headlight Adjust the headlight as described in Chapter Nine 14 Install the front fork as described in this chapter 15 Install the front wheel as described in Chapter Ten 16 Adjust the front steering as described in this chapter 17 Install the fork stem cap over the nut FXSB and FXEF Models Removal Refer to Figure 75 1 Remove the front wheel as described in Chapter Ten 2 Remove the fuel tank as described in Chapter Nine 3 Remove the handlebar assembly as described in this
21. fork assembly 13 Place the slider in a vise with soft jaws and securely tighten the fork top plug Figure 42 FRONT SUSPENSION AND STEERING 579 14 Push the fork slider and damper rod Figure 43 into the fork slider Insert a Phillips screwdriver through the opening in the bottom of the fork slider and guide the damper rod end into the receptacle in the base of the slider Remove the screwdriver 15 Install anew washer onto the damper rod Allen bolt 16 Apply a nonpermanent threadlocking compound to the damper rod Allen bolt threads prior to installation In sert the Allen bolt Figure 44 through the lower end of the slider and thread it into the damper rod Tighten the bolt securely CAUTION To protect the oil seal lips place a thin plas tic bag on top of the fork tube Before in stalling the seal in the following steps lightly coat the bag and the seal lips with fork oil 17 Slide the fork slider bushing A Figure 45 oil seal spacer B and oil seal C with the letters facing up down into the fork tube receptacle Figure 46 NOTE A fork seal driver is required to install the fork tube bushing and seal into the fork tube A number of different 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 correct di mensions to slide over the fork tube and seat against the seal When selecting or fabricat ing a driver too
22. he front or rear brake while listening to the antidive solenoid When the brake is applied a faint click should be heard or a vibration can be felt on the solenoid 5 Check the antidive system as follows a Install a no loss air gauge on the air control valve fitting See Figure 62 and Figure 63 b Turn the ignition switch off c Apply the front brake and bounce the front end while watching the air gauge The air pressure should fluc tuate as the front end moves up and down d Turn the ignition switch on and repeat substep b The air pressure should stay constant as the front wheel bounces up and down 6 If necessary service the air control antidive system as described in this chapter FRONT FORK AIR CONTROL AND ANTIDIVE SYSTEM SERVICE AND TESTING Removal Installation 1984 1987 FXRD and FXRT models Refer to Figure 64 1 Disconnect the negative battery cable from the battery 584 CHAPTER ELEVEN FRONT FORK AIR CONTROL 1984 1987 FXRD AND FXRT MODELS 13 1985 1986 3 CESS oi amp x Bolt 17 Fork slider tube Bolt cap washer Lockwasher 18 Valve assembly Lockwasher 19 Valve body Nut 1985 20 Solenoid Wire terminal 21 Elbow 1985 Cable strap 22 Accumulator Hose clamp 23 Valve stem 1986 O ring 1985 24 Fitting 1985 Valve cap 1986 25 Wire terminal socket Fork slider tube cap 26 Hose Gasket 27 Flat washer Banjo bolt 28 Spacer and washer Tube 29
23. he front steering is adjusted as described in this section 10 Install the front fork as described in this chapter 11 Install the brake hose bracket at the bottom of the fork stem bracket 12 Install the front wheel as described in Chapter Ten 13 Adjust the front steering as described in this chapter 14 Install the fork stem cap over the nut FLH and FLT Series Models Removal Refer to Figure 76 1 Remove the front wheel as described in Chapter Ten 2 On 1986 1998 FLHTC series models remove the light bar and outer fairing as described in Chapter Fifteen 3 On FLTC series models remove the instrument panel and handlebar 4 Remove the fuel tank as described in Chapter Nine 5 Remove the handlebar assembly as described in this chapter Position the handlebar so that the control cables are not kinked or damaged 6 On models with the air control system remove the air control system from the upper fork bracket as described in this chapter 7 Remove the front fork as described in this chapter 8 Remove the brake line bracket at the lower fork stem bracket 9 Disconnect the electrical connectors from the main cir cuit board 10 On models so equipped straighten the lockwasher tab away from the fork stem nut Then loosen and remove the nut lockwasher and main circuit board 11 Remove the upper fork bracket from the steering stem NOTE To prevent the steering stem from falling out hold onto the steering stem when re
24. hose routing through the frame prior to removal Then remove the hose assembly 11 Installation is the reverse of these steps while noting the following a Install a new O ring Figure 71 and apply a light coat of oil to it b Install the air tube assembly onto the top of the fork assembly and install the hex bolts through the banjo bolts Tighten the hex bolts to 97 142 in lb 11 16 Nem c Pressurize the system and check for leaks Antidive Solenoid Testing Refer to Figures 64 66 1 Disconnect the switch leads 2 Connect the ohmmeter leads to both switch leads The specified resistance is 10 20 ohms 3 Connect one ohmmeter lead to one of the antidive sole noid leads Touch the other lead to the antidive solenoid housing The resistance should be infinity 4 Replace the antidive solenoid if it failed either test CHAPTER ELEVEN Banjo fitting Air tube A i Fork tube Antidive Solenoid Removal Installation 1984 1987 FXRT and FXRD models Refer to Figure 64 1 Remove the front fork air control assembly as de scribed in this chapter 2A On 1984 1985 models disconnect the hose from the hose fitting Then unscrew and remove the hose fitting nut washer and O ring 2B On 1986 1987 models disconnect the hose from the banjo fitting Then unscrew and remove the banjo bolt banjo fitting and O rings 3 On early models only remove the nut from the end of the plunger body
25. ht Up to 150 Ibs 68 kg add For each additional 25 Ibs 11 kg add 1 7 1 7 Passenger weight For each additional 50 Ibs 23 kg add 1 5 10 Luggage weight For each additional 10 Ibs 4 5 kg add 1 7 3 21 Maximum pressure 25 172 35 241 Table 5 FRONT SUSPENSION TORQUE SPECIFICATIONS in Ib Fork air control system Air tubes banjo bolts 1984 1994 FXRD FXRT and FXRS SP models 25 30 34 41 Air accumulator bracket bolts 1984 1987 FXRD and FXRT models 30 35 41 47 Antidive solenoid housing bolts 1984 1987 FXRD and FXRT models 155 190 17 21 Air tubes flange nuts 1988 1994 FXRT and FXRS SP 17 23 Antidive switch bolts 1986 1996 FLH and FLT series models 25 30 34 41 1986 1996 FLHT and FLHTC models 25 30 34 41 Air tube assembly hex bolts 1997 1998 FLH and FLT series models 97 142 11 16 Antidive solenoid banjo bolts 97 124 11 14 Fork tube pinch bolts FXR series models 1984 1987 FXR FXRS FXRD and FXRT Upper 21 27 28 37 Lower 30 35 41 47 1987 FXLR FXRS and 1988 1992 FXR Upper and lower 25 30 34 41 1993 1994 FXR 1999 FXR2 and FXR3 Upper and lower 30 35 41 47 FXWG FXSB and FXEF 25 30 34 41 FLH and FLT series models 1984 1990 25 34 1991 1998 40 54 Fork tube plug FLH and FLT series models 50 55 68 75 Fork stem and bracket FXR series models Fork stem nut or bolt See text Upper bracket to fork stem pinch bolt 1984 1987 FXR FXRS FXRD and FXRT 2
26. ide a new lower dust seal and the lower bearing onto the steering stem until the bearing stops on the raised shoulder 6 Align the lower bearing with the machined shoulder on the steering stem Press or drive the lower bearing onto the steering stem until it bottoms Figure 83 STEERING PLAY ADJUSTMENT If aftermarket accessories have been installed on the steering assembly they must be removed before attempt ing to adjust the steering play FXR and FX Series Models 1 Use a floor jack centered under the frame Support the motorcycle with both the front and rear wheels the same 598 distance off the ground If necessary place a wooden block s under the rear wheel until the motorcycle is level 2 On models so equipped remove the windshield as de scribed in Chapter Fifteen 3 If any control cable is routed so that it pulls the front end one way or the other disconnect it 4 Loosen the lower bracket pinch bolts 5 Place a piece of masking tape transversely across the leading edge of the front fender 6 Swing the handlebar so that the front wheel faces straight ahead 7 Place a pointer on a stand so that the tip points to the center of the fender when the wheel is facing straight ahead 8 Lightly push the fender toward the right side until the front end starts to turn by itself Mark this point on the piece of tape 9 Repeat Step 8 for the left side 10 Measure the distance between the two marks on the tape Fo
27. into the air manifold recess FRONT SUSPENSION AND STEERING O STEERING STEM AND BRACKET 1988 1999 FXR SERIES MODELS Bolt Bearing Washer Bearing race Upper fork Frame steering head bracket Dust shield Bolt Steering stem and Bolt lower bracket Dust cap Bolt 10 Position the smaller outer diameter of the plunger spring going in first and install the spring and install the plunger 11 Coat the plunger body threads with Loctite Pipe Seal ant with Teflon and thread the plunger body into the air 591 manifold Tighten the plunger body using the same tool and method used in Removal in Step 5 12 Install the spacer washer antidive valve and valve housing On early models only install the nut onto the end of the plunger body and tighten securely 13A On 1984 1987 models install a new O ring into the groove machined above the plunger body threads Then install the hose fitting on the plunger body 13B On 1986 1987 models perform the following a Install two new O rings into the banjo fitting grooves b Then slide the banjo fitting over the plunger body c Install the banjo bolt and tighten to 97 124 in lb 11 14 Nem 14 If the ground connector was removed from the air fork manifold perform the following a Apply Loctite Pipe Sealant with Teflon to the screw threads before installing the screws b Move the ground connector into position and install the two screws Tighten the scre
28. it ting b Thread the hose fitting into the end of the plunger body c Securely tighten the nut washer and O ring 15B On 1986 1987 models perform the following a Install two new O rings into the banjo fitting grooves b Then slide the banjo fitting over the plunger body c Install the banjo bolt and tighten to 97 124 in lb 11 14 Nem 1988 1998 FXRT FXRS SP and FXRS Con models Refer to Figure 65 1 Remove the front fork air control assembly as de scribed in this chapter 2A On 1988 1991 models loosen and remove the banjo bolts banjo fitting and two O rings 2B On 1992 1998 models loosen and remove the fitting and O ring 3 Remove the antidive solenoid and its housing rubber washer washer and O ring 4 On 1984 models use a spanner wrench and unscrew the plunger body from the antidive valve If a spanner wrench is not available thread two thin jam nuts onto the plunger body and lock them together 5 Thread two thin jam nuts onto the plunger body and lock them together Unscrew and remove the plunger body from the bottom of the air manifold 6 Remove the spring plunger and O ring from the plunger body 7 If necessary remove the two tubes from the top of the air manifold CAUTION When removing the tube s in Step 8 do not remove the spacer sleeves 8 Carefully pull and remove the air tube from the air manifold Remove the O ring installed between the tube and air manifold seat Repeat for the o
29. l it must have sufficient weight to drive the bushing and oil seal into the fork tube A fork seal and cap installer JIMS part No 2046 is used for this procedure 18 Slide the fork seal driver down the fork tube and seat it against the oil seal Figure 47 580 CHAPTER ELEVEN 19 Operate the driver and drive the fork slider bushing and new seal into the fork tube Continue to operate the driver until the stopper ring groove in the tube is visible above the fork seal Remove the fork seal driver tool 20 Install the stopper ring Figure 48 into the slider groove Make sure the retaining ring seats in the groove Figure 49 21 Install the fork tube as described in this chapter 22 Insert a clear plastic tube into the fork cap bolt open ing Figure 50 Attach a funnel to the plastic tube and re fill each fork leg with the correct viscosity and quantity of fork oil in Table 1 Remove the small funnel and plastic tube INSPECTION ALL MODELS 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 for bending nicks rust or other damage Place the fork tube on a set of V blocks and check runout with a dial indicator If the special tools are not available roll the fork tube on a large plate glass or an other flat surface Harley Davidson does not provide ser vice specifications for runout FRONT SUSPENSION AND STEERING
30. move the air valve cap Then depress the air valve and bleed the system 5 If necessary remove the valve as described under In spection in this chapter 6 On 1988 or later models disconnect the air hose from the fitting on the handlebar 7 Remove the handlebar riser nuts and move the handle bar back and lay it on the blanket covering the fuel tank 8 Remove the ignition fork lock assembly mounting bolts on the upper fork bracket 9 If not already removed disconnect the electrical con nectors from the antidive valve 10 On 1986 1987 models disconnect the hose from the antidive valve 11 Loosen and remove the two banjo bolts securing the air fork manifold to the fork tube bolts 12 Lift the air fork manifold up and remove it If the manifold contacts the inner fairing gently push the fairing back by hand to make room for the manifold 13 Installation is the reverse of these steps while noting the following a Install a new O ring in the bottom of the air mani fold b Position the antidive switch on the forks if re moved and reconnect the switch electrical leads c Install the upper banjo bolts using new washers Tighten banjo bolts to 25 30 ft Ib 34 41 Nem d Reconnect the air hoses after installing all air con trol components e Pressurize the system and check for leaks 1997 1998 FLH and FLT series models Refer to Figure 67 1A Onall FLHT series models remove the outer faring On FLHTC series models also r
31. nd against the base of the fork tube 2 Tighten the lower bolt B Figure 34 so it seats below the steel washer Do not overtighten because the damper rod will be damaged Make sure the tool is indexed prop erly against the steel washer 3 Following the manufacturer s instructions install the special tool upper bolt into the hole in the fork tube plug A Figure 35 Make sure the tool is indexed properly in the hole in the fork tube plug WARNING Be careful when removing the fork top plug because the spring is under pressure Pro tect eyes and face accordingly 4 Hold onto the fork tube and loosen the fork tube plug B Figure 35 Slowly loosen the special tool while un screwing the fork tube plug 5 When the fork tube plug is completely unscrewed from the fork tube loosen and remove the special tool from the fork assembly 6 Remove the fork tube plug and fork spring and drain out any residual fork oil Dispose of the fork oil properly 7 Turn the fork tube upside down and remove the damper rod and rebound spring 8 Inspect all parts as described in this section Assembly 1 Install a new O ring onto the fork top plug Figure 36 2 Install a new O ring onto on the fork cap bolt Figure 37 3 Before assembly coat all parts with Harley Davidson Type E Fork Oil or an equivalent fork oil 578 CHAPTER ELEVEN 4 Install the rebound spring A Figure 38 onto the damper rod and slide the damper rod B into
32. ng races with the steering head bear ing race installer tool JIMS part No 1725 following the manufacturer s instructions 4B If the special tools are not available install the bear ing 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 Figure 81 Do not contact the bearing race surfaces Drive the race into the steering head until it bottoms on the bore shoulder c Repeat substeps a c to install the lower race into the steering head 5 Apply bearing grease to the face of each race Steering Stem Lower Bearing Replacement Do not remove the steering stem lower bearing and lower dust seal unless they are going to be replaced The lower bearing can be difficult to remove If the lower bearing cannot be removed as described in this procedure refer the service to a Harley Davidson dealership Never reinstall a lower bearing that has been removed It is no longer true and will damage the bearing assembly 1 Install the steering stem bolt or nut onto the top of the 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 in Figure 82 Slide the lower bearing and lower dust seal off the steer ing stem 3 Clean the steering stem with solvent and dry it thor oughly 4 Position the new lower dust seal with the flange side facing up 5 Sl
33. pressed into the steering head Do not remove them unless they are going to be re placed 1 Wipe the bearing races with a solvent soaked rag and dry them with compressed air or a lint free cloth Check the races in the steering head Figure 77 for pitting 596 scratches galling or excessive wear If any of these condi tions exist replace the races as described in this chapter If the races are in good condition wipe each race with grease 2 Clean the bearings in solvent to remove all of the old grease Blow the bearing dry with compressed air without allowing the air jet to spin the bearing Do not remove the lower bearing from the fork stem unless it is to be re placed Clean the bearing while it is installed in the steer ing stem 3 After the bearings are dry hold the inner race with one hand and turn the outer race with the other hand Turn the bearing slowly The bearing should turn smoothly with no roughness Visually check the bearing Figure 78 for pit ting scratches or visible damage If the bearings are worn check the dust covers for wear damage or improper bear ing lubrication Replace the bearing if necessary If a bear ing is going to be reused pack it with grease and wrap it with wax paper or some other lint free material until it is reinstalled Do not store the bearings for any length of time without lubricating them to prevent rust 4 Check the steering stem lower bracket for cracks or damage Check
34. r pressure to reduce fork compression during braking The amount of antidive is dependent on the amount of air pressure applied to the system Air Pressure Adjustment 1996 1998 FLH and FLT series models WARNING Use caution when releasing the air from the front fork and the front fork air valve Mois ture and or fork oil might spurt out when the air pressure is released Protect eyes ac cordingly 1 Place the motorcycle on the jiffy stand 2 Remove the right saddlebag as described in Chapter Fifteen 3 Remove the front air valve cap Figure 61 4 Use a no loss air gauge to check air pressure Refer to the recommended air pressure listed in Table 4 5 Increase or decrease air pressure to achieve the desired ride and control CHAPTER ELEVEN 6 At the same time check and adjust if necessary the air pressure in the rear shock absorbers 7 Install the air valve cap s and the saddlebag All models except 1996 1998 FLH and FLT series WARNING Use caution when releasing the air from the front fork and the front fork air valve Mois ture and or fork oil might spurt out when the air pressure is released Protect eyes ac cordingly 1 Place the motorcycle on the jiffy stand 2A On 1984 1987 models remove the front air valve cap Figure 62 2B On 1988 1995 models remove the front air valve cap Figure 63 3 Use a no loss air gauge to check air pressure Refer to the recommended air pressure listed in Table
35. r proper bearing adjustment the distance should be 1 2 in 25 4 50 8 mm If the distance is incorrect per form Step 11 NOTE On FXWG models adjustment is made by loosening or tightening the fork stem nut or bolt NOTE If the adjustment is less than 1 in 25 4 mm slightly tighten the nut bolt or bearing seat Loosen the nut bolt or bearing seat if the adjustment is more than 2 in 50 8 mm 11A On 1984 1987 FXR except 1987 FXLR FXRS SP FXEF and FXSB models refer to Figure 72 and per form the following a Loosen the upper fork bracket pinch bolt and the lower bracket fork tube pinch bolts b Loosen or tighten the fork stem nut until the fall away distance is 1 2 in 25 4 50 8 mm c Recheck adjustment Then when correct tighten the pinch bolts to 21 27 ft Ib 28 37 Nem 11B On 1987 FXLR and FXRS SP and all 1988 1998 FXR models refer to Figure 73 and perform the follow ing a Loosen the upper fork bracket pinch bolt and the lower bracket fork tube pinch bolts b Loosen or tighten the fork stem bolt until the fall away distance is 1 2 in 25 4 50 8 mm c Recheck adjustment Then when correct tighten the pinch bolts to 25 30 ft Ib 34 41 Nem CHAPTER ELEVEN Bearing driver Steering stem Bearing 11C On FXWG FXSB and FXEF models refer to Fig ure 74 and Figure 75 and perform the following a Loosen the lower bracket fork tube pinch bolts b Turn the bearing seat located undernea
36. ry to rotate the fork tube slightly while pulling it down and out Remove the fork assembly and take it to the 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 15 Repeat for the other fork assembly Installation Fork Was Not Serviced 1 Install a fork tube through the lower fork bracket and install the rubber fork stop Figure 29 2 Continue to push the fork tube up through the top fork bracket until it bottoms against the upper fork bracket 3 Tighten the pinch bolt Figure 28 to 40 ft lb 54 Nem 4 Install the fork cap bolt Figure 27 onto the top of the fork tube and tighten securely 5 Install a new O ring onto each hex bolt Figure 30 and apply a light coat of clean engine oil to them 6 Install the air tube assembly onto the top of the fork as semblies and install the hex bolts through the banjo bolts Tighten the hex bolts to 97 142 in Ib 11 16 Nem 7 On models so equipped install the right saddlebag as described in Chapter Fifteen 8 Install the front fender and front wheel as described in Chapter Nine 9A On all FLHT series models install the outer fairing On FLHTC series models also install the storage box Re fer to Chapter Fifteen 9B On all FLHR series models install the headlight na celle as described in Chapter Nine 10 Apply the front brake and pump the front fork several times to seat the fork tubes
37. se the number of swings or loosen the nut to increase the number of swings 9 Tighten the lower bracket pinch bolts to the specifica tion in Table 5 10 Tighten the fork stem nut to the specification in Table 5 Bend the lockwasher tab against one flat on the nut tighten the nut if required to align the nut flat and lockwasher tab 11 Recheck the bearing adjustment 12 When the adjustment is correct reposition the rubber fork stops 13 Reinstall all parts previously removed Table 1 FRONT FORK OIL CAPACITY Oil Change 1984 1987 FXR and FXRS 1984 1987 FXRD and FXRT 1987 1994 FXLR 1988 1994 FXR and FXRS 1988 1994 FXRT and FXRS SP and FXRS Con 1999 FXR2 and FXR3 FXWG FXSB FXEF FLT and FLH series models Rebuild cc Table 2 FRONT FORK AIR CONTROL 1984 1994 FXR SERIES MODELS Recommended air pressure psi kPa Vehicle load Rider weight not exceeding 150 Ibs 68 kg Maximum pressure Front fork 4 8 28 55 Each additional 25 Ibs 11 kg add 2 14 Passenger weight For each 50 Ibs 23 kg add 1 7 20 138 Accumulator 1984 1987 FXRD and FXRT 5 30 34 207 30 207 Table 3 FRONT FORK AIR CONTROL 1984 1994 FLH AND FLT SERIES MODELS Recommended pressure psi kl 20 138 15 103 10 69 600 CHAPTER ELEVEN Table 4 AIR SUSPENSION ADJUSTMENTS 1995 1998 FLH AND FLT SERIES MODELS Recommended pressure psi kPa Front fork Rear shock absorber Rider weig
38. th the upper fork bracket until the fall away distance is 1 2 in 25 4 50 8 mm c Recheck adjustment Then when correct tighten the pinch bolts to 25 30 ft Ib 34 41 Nem 12 On models so equipped install the windshield as de scribed in Chapter Fifteen FLH and FLT Series Models 1 Use a floor jack centered under the frame Support the motorcycle with both the front and rear wheels the same distance off the ground If necessary place a wooden block s under the rear wheel until the motorcycle is level 2 Remove the windshield if so equipped and all other accessory weight from the handlebar and front forks that could affect this adjustment 3 If any control cable is routed so that it pulls the front end one way or the other disconnect it 4 Turn the wheel to the left as far as it will go and then let it go If the steering adjustment is correct the front wheel will swing from left to right three times and then stop near the center or straight ahead position If the adjustment is FRONT SUSPENSION AND STEERING 599 incorrect the number of swings past center is fewer or more than three times perform the following 5 Loosen the lower bracket pinch bolts 6 Slide both rubber fork stops a few inches up the re spective fork tubes 7 Straighten the lockwasher tab away from the fork stem nut and loosen the nut 8 Insert a drift punch into a notch in the bearing adjust nut Figure 74 Tighten the nut to decrea
39. the fork tube until it extends out the end of the fork tube 5 Install the oil lock piece Figure 39 onto the end of the damper rod 6 Position the fork spring with the closer wound coils going in first Figure 40 and install the fork spring into the fork tube 7 To protect the fork tube place a steel washer A Fig ure 34 over the fork damper rod and up against the base of the fork tube 8 Tighten the lower bolt B Figure 34 so it seats below the steel washer Do not overtighten because the damper rod will be damaged Make sure the tool is indexed prop erly against the steel washer 9 Position the fork tube plug onto the top of the fork spring 10 Install the special tool upper bolt into the hole in the fork tube plug A Figure 41 following the manufac turer s instructions Make sure the tool is indexed prop erly in the hole in the fork tube plug CAUTION While tightening the special tool do not jam the fork tube plug into the threaded portion of the fork tube Doing so will damage the threads on either or both parts 11 Hold the fork tube plug and slowly tighten the special tool while guiding the fork tube plug into the top of the fork tube B Figure 41 12 Place a wrench on the fork tube plug B Figure 35 and screw the fork tube plug into the fork tube while tight ening the special tool Once the fork tube plug has started to thread into the fork tube loosen the special tool and re move it from the
40. the threads at the top of the stem for dam age Check the steering stem bolt or nut for damage Thread it into the steering stem Make sure the bolt or nut threads easily with no roughness 5 Replace all worn or damaged parts Replace bearing races as described in this chapter 6 Replace the lower steering stem bearing Figure 79 and the dust shield as described in this chapter 7 Check for broken welds on the frame around the steer ing head If any are found have them repaired by a com petent frame shop or welding service familiar with motorcycle frame repair CHAPTER ELEVEN STEERING HEAD BEARING RACE REPLACEMENT The upper and lower bearing outer races are pressed into the frame Do not remove the bearing races unless re FRONT SUSPENSION AND STEERING Wooden block Head tube Stem nut Steering stem Dust seal and bottom race placement is necessary If they are removed replace both the outer race and bearing at the same time Never rein stall an outer race that has been removed as it is no longer true and will damage the bearing 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 80 Tap all around the race so neither the race nor the steering head is bent 3 Clean the steering head with solvent and dry it thor oughly 597 4A Install the beari
41. ther air tube and O ring 9 Remove all sealer residue from the plunger body and antidive valve threads 10 Install a new O ring into the air manifold recess 11 Position the smaller outer diameter of the plunger spring going in first and install the spring onto the plunger 590 12 Coat the plunger body threads with Loctite Pipe Seal ant with Teflon and thread the plunger body into the air manifold Securely tighten the plunger body 13 Slide the washer rubber washer and antidive sole noid onto the plunger body Install the housing onto the antidive solenoid 14 Install a new O ring into the groove above the threads on the plunger body 15A On 1988 1991 models perform the following a Install two new O rings into the banjo fitting and slide the banjo fitting onto the plunger body Thread the banjo bolt onto the plunger body until it is fin ger tight b Turn the banjo fitting so that its hose nozzle faces in the direction shown in Figure 65 Tighten the banjo bolt to 97 124 in Ib 11 14 Nem 15B On 1992 1998 models install the fitting with a new O ring 16 Ifthe air tubes were removed install them as follows a Install a new O ring into the air manifold b Carefully insert the air tube into the air manifold un til the taper on the end of the tube touches the O ring c Repeat for the other tube and O ring FLH and FLT series models Refer to Figure 66 1A On FLT 1984 1985 FLHTC and FLHS models per
42. tion on the fork tubes b Install a new O ring into the valve body air tube bore c Insert the flared end of the air tube into the valve body align the end of the tube with the fork cap Se cure the end of the tube with the O ring and valve body d Tighten the flare nut to 17 ft lb 23 Nem e Install the banjo bolts through the air tubes Make sure to place a washer on both sides of the air tube s as shown in Figure 65 Tighten the banjo bolts to 25 30 ft Ib 34 41 Nem f Reconnect the air hose Secure both ends of the hose with new hose clamps g On FXRT models install the spacers under the top cover and tighten the screws securely h Pressurize the system as described in this chapter and check for leaks i Adjust the headlight as described in Chapter Nine All 1984 1996 FLH and FLT series models except 1984 1996 FLHT and FLHTC Refer to Figure 66 1 Disconnect the negative battery cable as described in Chapter Nine CAUTION When removing the instrument panel in Step 2 do not turn the panel upside down because damping oil in the fuel gauge will run onto the gauge face and stain it NOTE Cover the fuel tank and front fender with a heavy cloth to protect them from accidental scratches or dents when removing the fol lowing components 586 0323 28 1984 1987 1988 1996 WMNAHEWNS Banjo bolt 22 Hose fitting 1984 1987 Washer 23 O rings 1988 1996 Air fork manifold 24 Hose fi
43. tting 1988 1996 Fork tube cap 25 Banjo bolt 1988 1996 O ring 26 Handlebar air reservoir Fork tube plug 1988 1996 O ring 27 Hose 1988 1996 Upper fork bracket 28 Engine guard Ground connector accumulator 1984 1987 Screws 29 Lockwasher 1984 1987 O ring 30 Bolt 1984 1987 Fork tube cap 31 Hose 1984 1987 O ring 32 Hose fitting Plunger 33 Engine guard plug Spring 1984 1987 Plunger body 34 Bolt 1984 1987 Spacer and rubber 35 Washer 1984 1987 washer 36 Valve stem 1984 1987 Solenoid 37 Cap 1984 1987 Solenoid cover 38 Ground terminal block Solenoid cover nut 1984 1993 O ring 1984 1987 39 Screw 1993 CHAPTER ELEVEN FRONT FORK AIR CONTROL 1984 1996 FLH AND FLT SERIES MODELS 2 Remove the instrument panel as described in Chapter Nine 3 Remove the air valve cap Then depress the air valve and bleed the system 4A On 1984 1987 models disconnect the air hose from the engine guard accumulator 4B On 1988 1998 models perform the following a Remove the handlebar riser locknuts from under the fork bracket b Remove the upper clamps and lift the handlebar up slightly c Disconnect the air hose from the fitting on the han dlebar d Set the handlebar aside to prevent damaging the control cables 5 Loosen and remove the air manifold banjo bolts and washers Disconnect any electrical connectors at the man ifold and remove the manifol
44. ushing slit C Figure 58 with a screwdriver and slide the bushing off the fork tube 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 582 15 Check the damper rod piston rings A Figure 59 for excessive wear cracks or other damage If necessary re place both rings as a set 16 Check the damper rod B Figure 59 for straightness with a set of V blocks and a dial indicator Figure 60 or by rolling it on a piece of plate glass Specifications for runout are not available If the damper rod is not straight replace it 17 Make sure the oil passage hole in the damper rod C Figure 59 is open If it is clogged flush it with solvent and dry it with compressed air 18 Check the internal threads in the bottom of the damper rod for stripping cross threading or sealer resi due Use a tap to true the threads and to remove sealer de posits 19 Check the damper rod rebound spring and the fork spring for wear or damage Service limit specifications for spring free length are not available If necessary replace both fork springs as a set 20 Replace the oil seal whenever it is removed Always replace both oil seals as a set FRONT FORK AIR CONTROL AND ANTIDIVE SYSTEM ADJUSTMENT AND INSPECTION All FLH FLT and some FXR series models are equipped with a front fork air control antidive system This system uses ai
45. ve to evacuate the air from the front fork air pipe system Unscrew and remove the core from the air valve Place the air valve core and cap in a reclosable plastic bag to avoid misplacing them 10 Refer to Figure 25 Unscrew and remove the hex bolts Figure 26 securing the banjo bolt on top of each fork tube Move the air tube assembly out of the way from the fork assemblies 11 Remove the fork cap bolt Figure 27 from the top of the fork tube 12 Loosen the pinch bolt Figure 28 at the base of the steering stem 13 Slide the fork assembly part way down and retighten the pinch bolt Figure 28 14 Place a drain pan under the fork slider to catch the fork oil 15 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 16 Remove the Allen bolt and drain the fork oil Pump the slider several times to expel most of the fork oil Rein stall the Allen bolt to keep residual oil in the fork 17 Remove the stopper ring from the fork slider 18 Lower the fork slider on the fork tube NOTE It might 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 directly apply a flame to the fork slider 19 There is an interference fit between the bushing in the fork slider and the bushing on the fork tube In order to re move the fork tube from the slider pull hard on the fork tube using quick in
46. ws securely to pre vent an air leak STEERING HEAD AND STEM FXR Series Models Removal Refer to Figure 72 and Figure 73 1 Remove the front wheel as described in Chapter Ten 2 Remove the fuel tank as described in Chapter Nine 3 Remove the handlebar assembly as described in this chapter Position the handlebar so that the control cables are not kinked or damaged 4 On models with the air control system remove the air control system from the upper fork bracket as described in this chapter 5 Loosen the fork stem nut on early models or the steer ing stem bolt on later models 6 Remove the front forks as described in this chapter NOTE Hold onto the steering stem when removing the upper fork bracket pinch bolt in Step 7 to prevent the steering stem from falling out 7 Loosen the steering stem pinch bolt and remove the upper bracket 8 Carefully lower the steering stem and lower bracket out of the steering head 9 Remove the upper dust shield from the steering head 10 Remove the bearing from the upper bearing race in the steering head 592 11 Inspect the fork stem assembly as described in this section Installation 1 Thoroughly pack both bearings with bearing grease 2 Make sure the steering head and stem races are prop erly seated 3 Apply a light coat of grease to the steering head races 4 Install the lower dust shield onto the lower bearing on the steering stem 5 Install the steering stem into the
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