Changing

Remove fork upper bracket bolt or filler screw and washer. Remove drain plug at the outside bottom of each slider tube and drain. Draining speed will be increased by gently flexing the fork as it empties. Replace drain plugs and pour specified amount of Harley-Davidson Type B Fork oil into each tube. 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.

Model

Year

Amount

Fork Oil Type

Wet

Dry

FX/FXE/ FXS

1972 and Earlier

5-1/2 oz.

6-1/2 oz.

Harley-Davidson Type B

1973 and Later

5 oz.

6 oz.

Harley-Davidson Type B

FL/FLH

Mid 1977 and Earlier

6-1/2 oz.

7 oz.

Harley-Davidson Type B

Late 1977 and Later

7-3/4 oz.

8-1/2 oz.

Harley-Davidson Type B

The fork filling device shown in Figure 2-33 will hasten and simplify the filling operation. The unit consists of a Neo-prene (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.

1. 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 2-33. Fork Filler Can Components

2. Select a tin tunnel (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.

3. 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.

4. 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 the stopper to a 5/8 in. diameter at the large end, and slightly under 1/2 in. diameter at the small end, straight taper between ends, to form the plug.

5. Slightly flare one end of a piece of 1/4 in. tubing (6), about 2 in. long and insert into plug (7). Attach filler can to plug with transparent flexible tubing (5) about 2 feet long. See Figue 2-34.

Figure 2-34. Filling Hydraulic Fork with Oil

6. Push the plug into the filler hole in fork top. Pour exacl amount of oil into can. Work fork up and down. Air escaping through oil in filler can as fork is pushed downward will cause the oil to bubble violently, but because the bottom of the can serves as a baffle, no oil will be lost. Compressing the fork forces air out, releasing it draws oil into fork.

7 After the can appears to be empty, allow several minutes for can to completely drain, then work fork once more. This assures getting into fork side the full quantity of oil poured into can.

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