DUO-GLIDE (NON-ADJUSTABLE). Remove upper bracket bolt (2, Fig. 2F-3) at top of each fork tube.

DUO-GLIDE (ADJUSTABLE) AND SERVI-CAR. Remove fork cover side panels or headlamp housing and fork filler screws (23, Fig. 2F-4).

ALL MODELS. Remove drain plug, Fig. 2F-3 at the outside bottom of each slider tube with a 3/16 in. Allen wrench and drain. Draining speed will be increased by gently flexing the fork as it empties. Replace drain plugs and pour 6-1/2 oz. of Harley-Davidson Hydra-Glide Fork oil into each tube, 7oz. if fork has been disassembled and washed. Measure amount very carefully. Flow of oil into tubes will be increased if fork is worked up and down during filling operation. Replace upper bracket bolts and tighten securely.

The fork filling device shown in Fig. 2F-1 will hasten and simplify the filling operation. The unit consists of a Neoprene (not rubber) stopper to fit the hole in the top of the fork, a length of flexible tubing, a funnel and an appropriate size can, soldered to the top of the funnel.

To make a filler can, drill a dozen 1/4 in. holes in the bottom of a one quart tin can (2), near the outside edge. Shape the bottom of the can with a light hammer so that it is dished upward to assure complete draining of oil through the holes.

1. Bail

2. Filler can

3. Tin funnel

4. Metal tubing

5. Flexible tubing

6. Metal tubing

7. Rubber plug

8. Fork tube cap

Figure 2F-1. Fork Filler Can Components

Figure 2F-2. Filling Hydraulic Fork with Oil

Select a tin funnel (3) with the funnel mouth about the same size as the bottom of can (2). Swage and shape the funnel spout so that a piece of 1/4 in. metal tubing (4), about 2 in. long, (a piece of fuel line is suitable) can be soldered into it. Solder (3) onto the bottom of (2). Improvise and attach bail (1) to the filler can.

Make plug (7) from a rubber bottle stopper purchased from a drug store. Rubber stopper should be 1 in. to 1-1/8 in. long, and its largest diameter about 5/8 in.

Hold rubber stopper in vise and drill a 3/32 in. hole lengthwise through the center. Then enlarge the hole with a 1/4 in. drill. After hole is drilled in the stopper, insert a 1/4 in. rod through the hole and grind

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