Removal
Warning! To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury.
1. Purge the fuel supply hose of high pressure gasoline. Disconnect fuel supply hose from fuel pump module. See 4.4 FUEL TANK: XL MODELS or 4.5 FUEL TANK: XR 1200X.
Warning! To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding.
2. Remove main fuse.
3. Remove fuel tank. See 4.4 FUEL TANK: XL MODELS or 4.5 FUEL TANK: XR 1200X.
4. Turn front forks full left lock.
5. See Figure 2-240. See Figure 2-241. Using a 5/64 drill bit, carefully drill a hole in the center of the lock pin.
![](https://motoinstruction.ru/img/harley/12/117857.jpg)
Figure 2-240. Fork lock pin
![](https://motoinstruction.ru/img/harley/12/117858.jpg)
Figure 2-241. Drilling lock pin
Note. Take time to carefully orient drill bit to center of lock pin. If drill bit slides off-center removal of lock pin will be difficult.
6. See Figure 2-242. To remove lock pin, insert a screw extractor into the drilled hole. Hold body of screw extractor with a pliers or tap handle and using a small hammer gently "tap" on the pliers or tap handle to remove lock pin.
![](https://motoinstruction.ru/img/harley/12/117859.jpg)
Figure 2-242. Removing lock pin
7. Remove lock assembly.
Installation
1. Insert new lock assembly in frame lock housing.
2. Align lock pin hole in new lock assembly with hole in the frame lock housing.
3. Drive new lock pin in position (flush with frame lock housing).
4. Install fuel tank. See 4.4 FUEL TANK: XL MODELS or 4.5 FUEL TANK: XR 1200X.
5. Verify proper operation of fork lock.
- a. Turn front forks fully to the left.
- b. Insert key into fork lock. Turn key 90 degrees clockwise.
- c. Verify that front forks are locked and cannot be turned.
- d. Turn key 90 degrees counterclockwise and remove from fork lock.
- e. Verify that front forks are now free to fully turn right and left.
6. Install main fuse.