Note

Late 1977 and later forks do not have removable bushings. If slider is worn to excessive looseness on fork tube, slider must be replaced.

3. Damper valve stud locknut (2)

5. Slider tube snap ring

6. Damper tube bushing gasket(2)

7. Damper tube lower bushing (2)

8. Damper valve stud gasket (2)

11 Spring ring washer (2) 12. Upper oil seal felt washer (2) 13 Upper oil seal (2)

15. Slider upper and lower bushing (2 each)

Figure 2-37. Fork Side (Early 1977 and Earlier)

The front fork slider bushings (15, Figure 2-3,7) may be replaced using four special tools.

1. Part No. 96255-50, Fork Slider Bushing Puller.

2. Part No. 96287-50A. Bushing Driver and Guide.

4. Part No. 96300-50, Bushing Reamer and Pilots.

To remove upper fork slider bushings, position fork slider in vise as shown in Figure 2-43.

Remove spring ring, steel retaining washer and felt wiper from slider upper end. Pry out oil seal with large screwdriver.

Install Fork Slider Bushing Puller, Part No 96255-50, so the three claws expand inside the tube under the upper, or shorter bushing. Place puller cap in oil seal counterbore, apply oil to screw threads and steel washer. Turn nut down against puller cap and use engine sprocket wrench on nut to extract bushing.

Remove lower bushing in the same manner New, replacement bushings are installed with Fork Slider Bushing Driver and Guide, Part Numbers 96287-50A and 96288-50.

Wash out fork slider and lubricate slider bore with engine oil. Position new lower bushing in bushing driver guide to compress bushing, then place driver guide with bushing in slider oil seal counterbore as shown in Figure 2-44.

Drive bushing through the driver guide into fork slider. Bushing is positioned correctly in slider bore when second groove from top on driver is flush with top edge of driver guide. Do not drive bushing deeper than specfiied, or it will collapse enough so it cannot be finish-reamed.

Install upper bushing in the same manner lower bushing was installed. Drive it into slider until lower groove on driver is flush with top of driver guide. This positions upper bushing 1/16 in. below slider oil seal counterbore.

The Fork Slider Bushing Reamer with pilots. Part No. 96300-50, is used to ream the bushings to finished size.

Figure 2-38. Fork Rebushing Tools

Attach long pilot to reamer as shown in Figure 2-45. The long pilot fits into the unfinished lower bushing, acting as a guide, while reaming the upper bushing. Do not drop reamer into bushing. Slowly lower reamer into cutting position and ream bushing, turning reamer clockwise. Continue turning reamer clockwise as it is being extracted when cut is finished.

Remove long pilot from reamer and attach short pilot. Finish lower bushing in same manner as upper bushing. Use caution when passing reamer cutters through the upper bushing.

ASSEMBLING FORK SIDES (Figures 2-35, 2-37)

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

INSTALLING FORK STEM AND BRACKET ASSEMBLY, FORK SIDES AND ADJUSTING STEERING HEAD BEARINGS (Figures 2-35. 2-36)

Assembly is the reverse of disassembly Apply a heavy coating of grease to bearing cones.

After fork sides are assembled to upper and lower bracket, tighten fork bracket clamping bolts (1) to 22 to 26 ft-lbs torque.

Assemble front fender, brake caliper and wheel to motorcycle before checking head bearing adjustment.

Fork should have free movement to either side. There should be no noticeable shake or sideways movement of the front fork. To adjust steering head bearings, tighten or loosen head bearing nut (20) as required, while tapping on bracket (22).

When bearings are correctly adjusted, install fork stem nut (18) and bend up tab on lockwasher (17).

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