INSTRUCTIONS -J08 REV. 0-28-99 GENERAL This kit is designed for installation on 996 to 999 FXSTSB model motorcycles. We recommend this kit be installed by a factory trained technician at an authorized Harley-Davidson Dealership. FXSTSB (SPRINGER) FRONT END KIT This kit is designed for use with a 2 in. front wheel. Do not use any other front wheel with this kit. Use of a different front wheel could adversely affect handling which could result in death or serious injury. A Service Manual is necessary for performing the following detailed Assembly and Installation procedures. A Service Manual for your motorcycle is available from your Harley- Davidson Dealer. See Illustrations for component Part Numbers and Locations. The rider s safety depends on the correct installation of this kit. USE THE APPROPRIATE SERVICE MANUAL PROCEDURES. If the procedure is not within your capabilities or if you do not have the correct tools, have your Harley-Davidson Dealer perform the installation. Improper installation could result in death or serious injury. Harley-Davidson has designed and manufactured this front end according to our very stringent and well-tested standards. Modifying the FXSTSB Springer front end in any way that changes our original design may lead to an accident which could result in death or serious injury. The components of your FXSTSB Springer front end and their design relationship to each other are very important. Altering these relationships by modifying the FXSTSB Springer front end could adversely affect the handling of the motorcycle which could result in death or serious injury. Do not install this front end kit on any non-approved motorcycle. Do not install on three-wheeled vehicles of any kind. Installation of the FXSTSB Springer front end on anything other than Softail models could result in death or serious injury. Use only Dunlop D402F tires with this kit. Using any other tire, or a tire with a higher aspect ratio, could allow the front wheel to bind on the fender during hard stops or big bumps, which may lead to an accident which could result in death or serious injury. DO NOT use front end components that have been remanufactured (straightened, plated, welded) in any way. There can be no certainty that remanufactured front end components will have the strength of the original, unchanged components. Using remanufactured components may lead to an accident which could result in death or serious injury. FXSTSB model motorcycles were NOT designed for sidecar use. The FXSTSB Springer fork was NOT designed for sidecar use. DO NOT use either the motorcycle or any FXSTSB Springer fork equipped vehicle with a sidecar. Use of any FXSTSB Springer fork equipped vehicle with a sidecar may lead to an accident which could result in death or serious injury. INSTALLATION Bearing Races and Fork Assembly Refer to the applicable Service Manual for Bearing Race and Fork Assembly procedures. Lower Springer Refer to the applicable Service Manual for Lower Springer Assembly and Installation procedures. Springer Steering Head Bearing Adjustment Refer to the applicable Service Manual for Springer Steering Head Bearing Adjustment procedures. Headlamp Refer to the applicable Service Manual for Headlamp Assembly and Installation procedures. of 5
, Page (Illustration ) Legend Illustration. Spring and Rigid Fork Components Subassemblies P/N 4690-00 (FXSTSB) Nut, acorn (4) 7680W 2 Lockwasher 722 Washer (5) (See Illustration 2 also) 682 4 Decal, shock 6600-88 5 Washer, spring rod (2) 65 6 Reflector, right side amber 59289-92 7 Reflector, left side amber (not shown) 59290-92 8 Front shock absorber 5448-88A 9 Spring bridge 46062-88 0 Retainer, spring upper (2) 46060-88 Cups, rebound spring (2) 46057-88 2 Spring cup, compression spring (2) 46056-88 Spring, compression outer (2) 46055-88 4 Spring, compression inner (4) 46054-88 5 Upper springs (2) 4605-88 6 Seat, spring (4) 4597-88 7 Travel bumper (4) 4596-88 8 Bushing, spring rod (2) 4595-88 9 Assembly, spring fork 4562-95 20 Assembly, rigid fork 45600-95A 2 Nut, acorn, lower spring rod (2) 45567-88 22 Spring rod, lower (2) 45566-88 2 Spring rod, upper (2) 4554-88 24 Screw 5 25 Label, spring bridge 492-88 26 Rubber bumper 456 27 Shock label 5429-97 Illustration. Spring, Rigid Fork and Riser Components Subassembly P/N 46206-00 (FXSTSB) 28 Screw (2) 855B 29 Nut, acorn 7959 0 Washer, rubber 6829 Riser (2) 56546-95 2 Cap (2) 56547-95 Rubber bushing (4) 556-86 4 Bearing adjuster 4806-88 5 Bolt, riser (2) 45544-88 6 Upper triple clamp 45485-95 7 Pinch bolt 450A 8 Screw 58 9 Clip, throttle cable 090 40 Clip, brake line (2) 0076 4 Cable tie (2) 0065 42 Cable tie (4) 0006 4 Washer 670 44 Clamp 47-86 45 Ground spring 46059-90 46 Washer (2) 675 47 Capscrew (4) 494A 48 Locknut (2) 7768W 49 Nut 75 50 Screw 594 5 Dust shield 486-80 52 Bearing, upper 4845-60 -J08 2 of 5
M Y O R LE S Date 0/99 i087.eps 25 29 47 5 0 7 2 9 0 6 4 4 46 45 48 5 7 8 22 5 52 24 28 2 5 40 22 8 9 6 4 42 27 7 44 4 50 26 4 28 40 2 49 8 6 O T S O N H AR LE Y- DA V ID C C 4 2 20 9 Illustration. Spring and Rigid Fork Components-Subassemblies P/N 4690-00 and P/N 46206-00 -J08 of 5
Date 0/99 i08.eps Only listed components are included in Subassembly Kits P/N 4690-00 and P/N 46206-00. All others shown for reference purposes only. 70 Fender 70 56 65 66 7 67 68 7 69 6 72 62 54 5 54 58 57 59 55 60 6 Illustration 2. Lower Fork Components-Subassembly Kits P/N 4690-00 and P/N 46206-00 Axle and Caliper Components included in Wheel and Brake Kit P/N 4849-00 Subassembly Kit P/N 4690-00 5 Ball, spherical bearing (4) 94 54 Race, spherical bearing (4) 940 55 Bearing, spherical (2) 99 56 Locknut 7667 57 Nut, acorn (4) 7627 58 Pivot stud, rigid fork to rocker (2) 45684-90 59 Washer (4) 45662-88 60 Pivot stud, spring fork to rocker (2) 4568-90 6 Jam nut, bearing retainer (2) 45659-88 62 Bearing retainer, rigid fork (2) 45655-88 6 Front rocker, right 45646-95 64 Front rocker, left (not shown) 45647-95 65 Link, brake reaction 4040-88B Subassembly Kit P/N 46206-00 66 Locknut 7667 67 Nut, shaft 7588 68 Washer 6498 69 Washer 67 70 Cotter pin (2) 54 7 Screw, brake link to bracket 4747 72 Assembly bracket, caliper mounting 44044-00 7 Spacer, rubber () (See Illustration also) 244 -J08 4 of 5
Date 0/99 i084.eps 78 75 84 84 80 74 80 Fender NOT included in Kit. Only listed components are included in Subassembly Kits P/N 4690-00 and P/N 46206-00. All others shown for reference purposes only. 7 82 76 79 8 85 77 8 Bearing must be pressed into fender Illustration. Headlamp and Fender Components-Subassembly Kits P/N 4690-00 and P/N 46206-00 Subassembly Kit P/N 4690-00 74 Bracket, headlight mounting 67892-9 75 Bolt 24 76 Pivot screw (2) 278 Subassembly Kit P/N 46206-00 77 Nut (2) 75 78 Assembly, headlight 6784-00 79 Washer (2) 6409 80 Rubber washer (2) 679W 8 Insert, fender (2) 5904-9 82 Pivot link (2) 4042-9 8 Bearing 74-90A 84 Screw (2) 297 85 Screw (2) 272 -J08 5 of 5