Note

Reference to vertical and horizontal center-lines applies to bracket and fork stem as positioned on arbor press (see Fig. 2F-12).

If both legs are twisted, place bracket assembly on arbor press as shown in Fig. 2F-13 with blocks placed under two low legs only (A and B). With press block placed across bracket and bar assembly, press until high legs (C and D) are in alignment.

If one leg is bent, place bracket and bar assembly on three straightening blocks, two blocks under straight leg and one block under low end of other leg. Place press block diagonally across bracket assembly to high leg until high leg is forced down and into alignment with the other three leg ends.

Place the fork stem and bracket assembly on the four straightening blocks located on the surface plate (see Fig. 2F-14). If the legs rest squarely on straightening blocks, the bracket assembly is correctly trued on a horizontal plane. If bracket is not true, press again, checking alignment after each operation.

Use a square to check if bracket assembly is bent, distorted or out of parallel on a horizontal plane as shown in Fig. 2F-15. Place bracket and bar assembly in a heavy vise and straighten using the Bending Bar.

Check fork stem alignment with Fork Stem and Bracket Aligning Gauge as shown in Fig. 2F-16. Use Bending Bar to bring stem into position. Recheckthe fork completely.

ASSEMBLING FRONT FORK (DUO-GLIDE NON-AD-JUSTABLE) (Fig. 2F-3)

Replace upper oil seal (23) and felt washer (22) in top of fork slider. Wash chips and oil from fork slider and position new oil seal in counterbore. Drive oil seal into counterbore and against seat with driver (Part No. 96250-50) and mallet as shown in Fig. 2F-17. Drive with light blows and stop immediately

Figure 2F-16. Checking Stem Alignment with Gauge

Figure 2F-15. Bending Bracket Legs Parallel 2F-10

Figure 2F-16. Checking Stem Alignment with Gauge when seal has bottomed. Insert spring ring washer (21) and spring ring (20). Position spring ring so its gap is directly over water drain hole in slider top.

Clamp a length of about 1 in. steel rod upright in a vise so that 13-1/2 in. extends above top of jaws. Assemble damper valve (19) with gasket (18), lower bushing (17) and lower bushing gasket (16). Make sure all of old gasket is removed before installing new part. Invert slider tube over length of rod in vise and drop damper valve assembly in place. Install snap ring (15) in notch provided in bottom of slider tube. Check clearance between snap ring and lower bushing. If clearance exceeds .004 in., remove snap ring, gasket and lower bushing and insert additional shims to bring to a maximum of .004 in. clearance.

Lubricate outside of slider tube with fork oil and slip slider assembly down over slider tube. Turn lock nut (13) on damper valve stud extending out bottom of slider. Work slider to check for bind. If bind is present, release lock nut, rotate slider 180 degrees and reassemble. Fasten fork slider covers (10) to fork bracket (9), and slip fork bracket over slider tubes. Adjust so 5-1/16 in. of slider tube extends above top of fork bracket and temporarily tighten bracket clamping studs (8).

Pour 7 oz. of Harley-Davidson Front Fork Oil intc each slider tube, insert fork springs (12) and turn in slider tube plugs (11).

Press lower head bearing guard (27) and greased lower head bearing (26) onto stem. Install stem in steering head on motorcycle. Grease and position upper head bearing (7). Turn on head bearing nut

Figure 2F-17. Inserting New Oil Seal

(6), until there is noticeable drag in bearing when fork is turned - then loosen nut enough so fork turns freely. Install handlebar and fork bracket (5), bracket cover (4). Securely tighten slider tube plugs. Loosen bracket clamping studs (8) and rotate slider tubes so flats on slider tube plugs are to the sides of the fork assembly. They must be in this position to have the slider tube plugs function properly. Install fork stem nut and then securely tighten bracket clamping studs.

Slip plug oil seal (3) on upper bracket bolt (2) and screw into slider tube plug. Replace handlebar, etc. Reassemble motorcycle in reverse order of disassembly.

ASSEMBLING FRONT FORK (DUO-GLIDE ADJUSTABLE AND SERVI-CAR) (Fig. 2F-4)

Follow procedure described for non-adjustable front fork except for the following points:

1. Position slider tubes in bracket (21) so top of slider tube is exactly 5-1/16 in. above top of bracket, and flat surfaces on slider tube plugs are directly toward side of motorcycle with filler screw (23) toward rear of fork.

Assemble remainder of fork and steering head in reverse order of disassembly.

shock absorbers

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