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9. Shock absorber tube

10. Wear rings

11. Boot

12. Damper tube sleeve

13. Lock ring

14. Seal

15. Screw

16. Washer

Figure 2-42. Fork Rebushing Tools Figure 2-43. Removing Fork Slider Bushing r

Figure 2-44. Installing Fork Slider Bushing

Figure 2-45. Reaming Fork Slider Bushing

Figure 2-44. Installing Fork Slider Bushing

Slowly start cut, turning reamer clockwise. When removing reamer after bushing is reamed, continue turning clockwise and apply a slight upward pressure to remove reamer from the finished bushing. Install the short reamer pilot, shown under 3, Figure 2-42, on reamer to ream the lower bushing. The Allen wrench provided with the tool set is used to tighten or loosen reamer pilots on the reamer body.

ASSEMBLING FRONT FORK SIDES (Figures 2-39, 2-41)

Assembly is the reverse of disassembly with the following exceptions: Fill fork sides with specified amount of Harley-Davidson, Type B, fork oil.

INSTALLING STEM AND BRACKET ASSEMBLY, FORK SIDES AND ADJUSTING STEERING HEAD BEARINGS (Figure 2-39)

Assembly of the fork is the reverse of disassembly. Assemble the head cups, races, bearing cones and dust shields. Apply a heavy coating of Harley-Davidson Grease-All grease to bearing cones.

Insert fork lower bracket stem (23) up through steering head and assemble upper bracket (16) and stem nut (14) loosely. Install fork sides (6). With forks correctly aligned, tighten fork tube caps (1) with pinch bolts (4) loose. Install front fender and front wheel.

Figure 2-45. Reaming Fork Slider Bushing

With fork sides, wheel and fender reassembled, fork should have smooth free movement to either side. There should be no appreciable shake or sideways movement of the front fork. To adjust steering head bearings, tighten or loosen stem nut (14) as required, while tapping on bracket (16). When bearings are correctly adjusted, tighten pinch bolts (4 and 15) to 22 to 26 ft-lbs torque.

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