HOME ASSEMBLY sm03227 TOOL NAME PART NUMBER FORK SEAL DRIVER B-45305 1 2 3 4 FORK TUBE HOLDER HD-41177 PRO-LEVEL OIL GAUGE HD-59000A TYPE E FORK OIL HD-99884-80 1. See Figure 2-103 . Insert seat pipe and piston assembly (23) with the rebound spring (14) into fork tube (9). 2. Slide bushing guide (19) down to bushing (28) on fork tube (9). Follow with spacer (18), oil seal (17), stopper ring (16), dust shield (15) and slider cover (7). 3. Install fork tube into FORK TUBE HOLDER (Part No. HD- 41177) mounted horizontally in a vise. 4. Fit stop oil lock piece (21) onto seat pipe (23). 5. See Figure 2-104 . Side seat pipe back into fork tube until seat pipe is centered in tube. 1.
Bushing guide 2. Spacer 3. Oil seal (chamfered lips must face oil) 4. Fork seal driver 6. See Figure 2-103 . Gently install slider (10) onto fork tube (9) and bushing (28). Figure 2-105. Assembled Fork Seal Driver 7. Thread seat pipe screw (1) and washer (5) into seat pipe (23) through bottom of slider (10). Draw fastener into seat pipe but do not torque. 11. See Figure 2-103 . Install stopper ring (16) into groove in top of oil seal. 8. Verify action of fork by sliding slider up and down fork tube. 12. Push dust shield (15) against oil seal and stopper ring 9. over fork tube in front of oil seal. 13.
Rotate slider cover to match any removal burrs to notch in slider and snap slider cover (7) into place. NOTE Chamfered lips on oil seal MUST face towards oil in fork. 14. Move slider through its full range of travel several times to verify alignment. Then, pulling down on slide to apply downward force on rebound spring (14), tighten seat pipe screw to 12-18 Nm (106-159 in-lbs ). 10. See Figure 2-105 . Holding Fork Seal Driver (4) together assemble in the following order. Tap oil seal (3), spacer FORK SEAL DRI VER (Part No. B- FORK TUBE HOLDER (Part No. HD-41177) vertically. With slider tube compressed, fill the fork with Harley-Davidson TYPE E FORK OIL (Part sm03226 No.
HD-99884-80) until it is approximately 91 mm (3.6 in.) from top of fork tube. 16. Slowly pump slider 8 to 10 times to exhaust air from assembly. Fully compress slider to determine oil level. NOTE Fork oil level is measured from top of fork tube, with spacer and spring removed and fork fully compressed. 17. Using the PRO-LEVEL OIL GAUGE (Part No. HD- 59000A), adjust the oil level to 91 mm (3.6 in.) from top of fork tube. 18. Pull out the slider (10) and install the rebound spring (14) in the fork tube with the tightly wound end at the bottom. 19. Install the washer (12) and spring collar (13). Figure 2-104.
Seat Pipe Centered in Fork Tube Wear safety glasses or goggles when servicing fork assembly. Do not remove slider tube caps without relieving spring preload or caps and springs can fly out, which could result in death or serious injury. (00297a) 2-84 2009 VRSC Service: Chassis Pipe Centered in Fork Tube Wear safety glasses or goggl assembly. Do not remove slider tu spring preload or caps and spring result in death or serious injury. e: Chassis Figure 2-104. Seat 2-84 2009 VRSC Servic es when servicing fork be caps without relieving s can fly out, which could (00297a)