INSTRUCTIONS. FLHR/C/S (Road King) FRONT END LOWERING KIT 1WARNING -J03242 REV General. Removal (Left and Right Forks) Kit Number

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1 INSTRUCTIONS -J04 REV General FLHR/C/S (Road King) FRONT END LOWERING KIT This kit is designed for installation on 00 and later FLHR/C/S Model Motorcycles. Road King models use the conventional type fork on both sides. IMPORTANT: The following parts (*) are not included in this kit and will need to be replaced during fork rebuilding: Qty Description Part Number Quad ring seal* Wear ring A Slider bushing Fork oil seal* A 6mm screw w/copper crush washer* A O-ring Kit Number The rider s safety depends upon the correct installation of this kit. Use the appropriate Service Manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley- Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00a) Removal (Left and Right Forks). Place suitable blocking under frame to raise front wheel several inches off the floor. For best results, use a hydraulic center stand on a level surface.. Refer to Touring Model Service Manual and remove front wheel, fender and brakes.. Refer to Touring Model Service Manual and remove headlamp nacelle. Kit Contents-Refer to Service Parts Illustration on Page 5 for locations. Qty Description Part Number Fork spring Rebound spring Bottom pipe comp This Front End Lowering Kit cannot be used independently. It must be used with FL Profile Low Rear Suspension Kit (Part Number 546-0B) or handling and cornering may be affected. This could distract the rider, causing loss of control and death or serious injury. This kit is not designed to be used with Sidecar installed. Any attempt to use this front suspension lowering kit with sidecar may cause handling or steering problems which could result in death or serious injury. 4. Loosen fork cap bolt from fork tube plug at top of fork tube, but do not remove. 5. See Figure. Standing at front of vehicle, loosen pinch bolt (with lockwasher) on right side of lower fork bracket, but do not remove. 6. Spray glass cleaner on fork tube above the rubber fork stop. After lubricating surfaces, move fork stop up fork tube until it contacts bottom of upper fork bracket. 7. Holding fork slider to prevent fork from dropping, remove fork cap bolt from fork tube plug. Slide fork tube down and out of upper fork bracket, fork stop, lower fork bracket and slider cover. i04808 Fork cap bolt Fork stop Pinch bolt Figure. Loosen Pinch Bolt on Lower Fork Bracket of 5

2 8. Thread fork cap bolt back into fork tube plug to prevent loss of oil while handling. 9. Move forks to bench area. Place suitable drain pan on floor beneath vise. 0. Repeat Steps -6 to remove left fork. i Remove fork spring from fork tube. 6. Remove fork assembly from fork tube holder. 7. Turning fork upside down, drain fork oil into drain pan. For best results, slowly pump fork tube and slider at least 0 times. 8. Install fork spring back into fork tube. 9. Place a shop rag on the floor, and turning fork assembly upside down, press end of spring against rag. While compressing spring to prevent rotation of damper tube, remove 6mm screw from end of fork slider. Use air impact wrench for best results. 0. Remove and discard fork spring. Figure. Fork Tube Holder (Part Number HD-477) Left And Right Fork-Disassembly. Remove nuts, lockwashers, flat washers and axle holder from studs at end of fork slider.. See Figure. Obtain FORK TUBE HOLDER (Part Number HD-477) and proceed as follows: i0480 a. Clamp end of tool in vise in a horizontal position with plastic knobs facing toward you. b. See Figure. With the fork cap bolt topside, clamp fork tube between rubber pads on inboard side of tool. Tighten knobs until fork tube is securely held. 4. Vise grip. Rubber pad. Plastic knob. Remove and discard damper tube.. Remove wear ring and rebound spring. Discard rebound spring. Do not expand or stretch retaining clip to remove from fork tube or clip may become bent or distorted.. Using pick tool, remove retaining clip between fork slider and fork tube. 4. Remove fork tube from fork slider. To overcome any resistance, use the fork tube as a slide hammer, that is, first push fork tube into fork slider and then pull it outward with a moderate amount of force. Repeat this sequence until fork tube separates from fork slider. 5. Slide fork oil seal, slider spacer and slider bushing off end of fork tube. Discard fork oil seal and slider bushing. 6. Remove the lower stop. Right and Left Fork-Assembly Exercise caution to avoid scratching or nicking fork tube. Damaging tube can result in fork oil leaks after assembly.. See Service Parts Illustration. Obtain new Damper Tube (Item 7, Part Number ) from kit. Obtain new Rebound Spring (Item 8, Part Number 467-0) from kit and install on opposite end. Install wear ring removed in step.. Fork tube plug. Fork tube holder. Vise 4. Wrench Flat Figure. Install Fork Tube into Holder. Remove fork cap bolt from fork tube plug. Remove quad ring seal. Save bolt but discard quad ring seal. 4. Using wrench flat, slowly unthread fork tube plug from fork tube. Be aware that fork tube plug is under spring pressure, so have a firm grasp on plug as the last thread is turned.. With the wear ring topside, slide new damper tube into fork tube, so that tube end drops through hole at bottom of fork tube. Install lower stop at end of damper tube.. Install fork slider in fork tube holder. Slide fork tube into fork slider. 4. If necessary, obtain new slider bushing (4) (Part Number , not included). Coat slider bushing ID with clean fork oil. Slide slider bushing down fork tube. 5. Slide slider spacer down fork tube until it contacts slider bushing. -J04 of 5

3 Place masking tape over edge of fork tube to avoid damaging lip of fork oil seal during installation. 6. Obtain new fork oil seal () (Part Number A, not included). Coat fork oil seal ID with clean fork oil. With the lip garter spring side facing down (toward the fork slider), slide oil seal down fork tube until it contacts slider spacer (). Remove masking tape from edge of fork tube. 7. Refer to Figure 4. Obtain the FORK OIL SEAL INSTALLER (Part Number HD-464) and proceed as follows: a. Slide the fork seal installer down the fork tube until it contacts the fork oil seal. b. See Figure 5. Using the tool like a slide hammer, drive fork oil seal (with slider spacer and guide bushing) down the fork tube until retaining clip groove is visible in fork slider ID. Do not expand or stretch retaining clip to install on fork tube or clip may become bent or distorted. i0485 c. Slide the retaining clip down the fork tube until it contacts the fork oil seal. Install retaining clip in the fork slider groove. 8 Obtain new Main Spring (Item 5, Part Number ) from kit. Install new fork spring into fork tube. : Make sure the main spring is installed with dense section of coils to the bottom. 9. Remove fork assembly from fork tube holder. 0. Place a shop rag on the floor, and turning fork assembly upside down, press end of spring against rag.. Install new 6mm screw with copper crush washer (Part Number A, not included). Slide screw through hole at bottom of fork slider and start into end of damper tube.. While compressing spring to prevent rotation of damper tube, tighten 6mm screw to -8 ft-lbs (5-4 Nm).. Remove fork spring from fork tube. 4. With the fork tube topside, clamp fork slider (not the fork tube) into fork tube holder. Install the drain screw at the bottom of the fork slider, if removed. Tighten the screw to 7-96 in-lbs (8- Nm). 5. Refer to Fork Oil Requirements and pour 50ml of Harley-Davidson Type E Fork Oil into fork tube. 6. Pump fork tube 0 times to remove air from system. 7. Adjust the fork oil level, so that it is 4.7 inches (06 mm) from the top of the fork tube. Proceed as follows: a. See Figure 8. Obtain the FRONT FORK OIL LEVEL GAUGE (Part Number HD-59000A). b. Loosen thumbscrew on metal ring and move it up or down the rod until the bottom of the ring is 4.7 inches (06 mm) from the bottom of the rod. Tighten thumbscrew. c. Push the handle on the cylinder all the way in. d. See Figure 9. Insert rod into top of fork tube until metal ring rests flat on top of fork tube. Figure 4. Fork Oil Seal Installer (Part Number HD-464) i0484 e. Pull out handle to suck fork oil from fork tube. Observe fork oil through transparent tube as it is drawn into cylinder. f. Remove rod from fork tube. Push handle into cylinder to eject excess fork oil into suitable container. g. If necessary, repeat Steps 7(c) through 7(f). Level is correct when no fork oil is observed being drawn through transparent tube. Incorrect amount of fork oil can adversely affect handling and lead to loss of vehicle control, which could result in death or serious injury. (0098a) Figure 5. Install Fork Oil Seal 8. Install new O-ring (Part Number , not included) onto fork tube plug. Compressing fork spring with end of fork tube plug, thread fork tube plug into fork tube. Tighten fork tube plug to -59 ft-lbs (0-79 Nm). : Do NOT overtighten or O-ring damage may occur. -J04 of 5

4 9. Install new quad ring seal (Part Number , not included) onto fork cap bolt. Thread fork cap bolt into fork tube plug to prevent loss of fork oil while handling. 0. Loosely install axle holder, flat washers, lockwashers and nuts on studs at end of fork slider.. Repeat steps thru 0 for left side fork. Incorrect amount of fork oil can adversely affect handling and lead to loss of vehicle control, which could result in death or serious injury. (0098a) Fork Installation (Left and Right). Remove fork cap bolt. Standing at front of vehicle, slide fork tube up and into slider cover, lower fork bracket, fork stop, and upper fork bracket. Install fork cap bolt.. Move rubber fork stop down fork tube until it contacts top of lower fork bracket. Lubricate surfaces with glass cleaner, if necessary. 4. Install pinch bolt (with lockwasher) on right side of lower fork bracket. Refer to Figure. Tighten pinch bolt to 0-5 ft-lbs (4-48 Nm). 5. Tighten fork cap bolt to ft-lbs (68-75 Nm). 6. Refer to instructions in Service Manual and install the front fender, wheel and brakes. i0489 i0487 Figure 8. Front Fork Oil Level Gauge (HD-59000A) Figure 9. Remove Excess Fork Oil : Cut out Fork Oil Requirements and SAVE for future use. Table. Fork Oil Requirements for 00 and later FLHR/C/S Front Suspension Lowering Kit FORK MODEL TYPE AMOUNT OZ ML IN. MM FLHR/C/S Conventional (Estimated) -J04 4 of 5

5 i048 Service Parts Part No Date 0/04 FLHR Front Suspension Lowering Kit Right and Left Fork O-ring. Spring * (Part No ). Wear ring 4. Damper tube * (Part No ) 5. Rebound spring * (Part No ) 6. Fork tube 7. Retaining ring 8. Fork oil seal 9. Slider spacer 0. Fork tube bushing. Slider bushing Lower stop. Fork slider 4. Plug 5. Flat washer 6. Copper washer 7. Screw (6mm) 8. Axle holder 9. Flat washer () 0. Lockwasher (). Nut () : * Denotes parts included in this kit. : Install Main Spring () with Dense Section of Coils Toward Bottom -J04 5 of 5

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