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Harley Davidson 2007 Softail. Service manual - page 10

 GENERAL
There are three varieties of hydraulic forks:

• All FLSTC, FLSTF and FLSTN Softail models use the type shown in Figure 2-88.

• All FXST, FXSTB and FXSTC Softail models use the type shown in Figure 2-89.

• FXSTD Softail models use the type shown in Figure 2-90.

Use the following information to service the models listed above. For other vehicles, see 2.22 SPRINGER FORK: FLSTSC.



REMOVAL
1. Remove front wheel and brake caliper. See 2.4 FRONT WHEEL: ALL BUT FLSTSC/FXSTD or 2.5 FRONT WHEEL: FXSTD

2. Remove front fender. See 2.30 FRONT FENDER: ALL BUT FLSTSC.

3. Remove the slider tube cap (1), spacer (2) and oil seal (3) from the top of one fork side.

4. Loosen the pinch bolt (4) and pull the fork side from the brackets.

5. Repeat Steps 3 and 4 for the other fork side.



DISASSEMBLY
ikwARNING
See Figure 2-88. The FLSTC/FLSTF and FLSTN models have a preloaded fork spring. Fork tube plug (5) is under spring pressure. Disassemble the fork tube(s) carefully. The spring can force parts from the tube unexpectedly, which could result in death or serious injury.

1. Support the vehicle so the front end is off floor and the forks are fully extended.

2. Remove the fork tube plug (5) and O-ring (6). Pull spring (7) out of slider tube (8). Remove drain screw (9) and washer (10), and drain the fork.

3. See Figure 2-89. On FXST/FXSTB/FXSTC, remove dust cover (23)and dust shield (47).

4. See Figure 2-90. FXSTD model front forks have a fork cap and dust shield. Remove fork cap (23) by inserting wooden block into slot in fork cap and tapping slightly then remove dust shield (36).

5. See Figure 2-88. Compress retaining ring (11) and remove the clip from the internal groove at the top of slider (12).

NOTE

Since there is little resistance to rotation when removing socket screw (13), the job is done more easily with an air impact wrench.

6. Use an alien wrench and remove socket screw (13) with washer (14) from the bottom end of fork slider (12). This

will free damper tube (15) and fork tube (8) so that they can be removed from slider.

7. The upper bushing (16) is a slight interference fit in slider (12). The upper bushing together with spacer (17) and oil seal (18) are removed by lightly hitting the upper bushing with the lower bushing (19) as the fork tube is pulled free of the fork slider in a quick continuous stroke. Continue this slide hammer action until the components are freed.

8. Push the damper tube (15) and damper tube spring (20) free of slider tube (8) by inserting a small diameter rod through the opening in the bottom of tube.

9. Remove lower stop (21) from the lower end of damper tube (15).

10. Damper tube ring (22) can now be removed from the grooves at the top end of damper tube (15). Lower bushing (19) should not be removed unless it is to be replaced. When replacing lower bushing (19), expand the new split bushing diameter only enough to fit over slider tube (8) and slide bushing into the bushing groove.



CLEANING AND INSPECTION

Thoroughly clean and inspect each part. If inspection shows

that any parts are bent, broken or damaged, those parts

should be replaced.

1. Inspect damper tube rings (22) on damper tube (15) and replace if worn excessively or damaged.

2. On FXSTD models, check dust shield where it rubs on slider tube. The tube should show a bright, shining surface, free of scoring or abrasions, and the dust shield should present a good continuous seal and not show excessive wear.

3. Replace either of the springs (7 or 20) if broken.

4. Inspect small hole in lower end of slider tube (8) and be sure it is not obstructed.

5. Be sure O-ring (6) is in good condition, without irregularities, and that it provides proper sealing when in place.

6. Install new screws (9 and 13) and washers (10 and 14).

7. Replace bent or damaged slider tube (8).

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