Changing fork oil: XL models
FASTENER | TORQUE VALUE | |
Fork, front, oil drain screw: XL 883N/R | 13-17 in·lbs | 1.5-2.0 Nm |
Fork slider tube cap | 22-58 ft·lbs | 29.9-78.7 Nm |
Drain forks: XL 883N/R
1. Place a drain pan under bottom of the fork slider.
2. See Figure 2-138. With the motorcycle upright (not resting on jiffy stand) and with the front fork pointed straight ahead, remove the drain screw and washer (1) from the bottom of the slider tube (4).
![](https://motoinstruction.ru/img/harley/12/117755.jpg)
Figure 2-138. Draining front fork oil: XL 883N/R: 1. Drain screw with washer; 2. Fork slider tube cap; 3. O-ring; 4. Slider tube
3. Drain fork oil by repeatedly compressing front suspension slowly.
Notes:
- If fork oil is emulsified, aerated or light brown in color, it has been contaminated by water. Replace the fork oil seals.
- Dispose of fork oil in accordance with local regulations.
4. Replace the drain screw and washer. Tighten to 13-17 in·lbs (1.5-2.0 Nm).
Fill forks: XL 883N/R
Warning! Incorrect amount of fork oil can adversely affect handling and lead to loss of vehicle control, which could result in death or serious injury.
Note. Extend the forks to relieve the spring preload by raising the motorcycle off the ground.
1. See Figure 2-138. Remove fork slider tube cap (2) with O-ring (3) from each slider tube (4). Replace the O-ring if damaged or worn.
2. Fill each fork with type TYPE "E"HYDRAULIC FORK OIL to specification. Refer to Table 2-20.
Table 2-20. Fork oil specifications: XL models
MODEL | oz | mL |
XL 883L | 12.3 | 364 |
XL 883N | 13.6 | 401 |
XL 883R | 12.4 | 366 |
XL 1200V/C/C ANV/CP/CA/CB | 12.4 | 366 |
XL 1200X | 11.4 | 337 |
3. Install each slider tube cap. Tighten to 22-58 ft·lbs (29.978.7 Nm).
Drain forks: XL 883L and XL 1200X/C/C ANV/CP/CA/CB/V
1. Remove the fork from the fork brackets. See 2.19 FRONT FORK: XL MODELS, Removal.
2. Remove the fork cap.
3. Turn the fork upside down over a pan and pump the slider to drain out the fork oil.
Removal
1. Remove front brake caliper(s). See 2.9 FRONT BRAKE CALIPER: XL MODELS.
2. Remove front wheel assembly. See 2.5 WHEELS.
3. Remove front fender mounting screws and locknuts. Remove fender. See 2.31 FRONT FENDER.
4. See Figure 2-139. Loosen, but do not remove, slider tube caps (1).
![](https://motoinstruction.ru/img/harley/12/117756.jpg)
Figure 2-139. Fork tube bracket: 1. Slider tube cap; 2. Upper pinch bolt; 3. Lower pinch bolt
5. Loosen front fork upper and lower bracket pinch screws (2 and 3). Remove fork assemblies from fork brackets.
![](https://motoinstruction.ru/img/harley/12/117757.jpg)
Figure 2-140. Front slider tube/slider assembly: XL models: 1. Upper bushing; 2. Spacer; 3. Damper tube; 4. Damper tube ring; 5. Spring; 6. O-ring; 7. Tube cap; 8. Rebound spring; 9. Slider tube; 10. Lower bushing; 11. Cover (all except XL 883N); 12. Dust seal; 13. Internal circle clip; 14. Oil seal; 15. Sleeve; 16. Pinch bolt; 17. Washer; 18. Screw; 19. Drain screw and washer (XL 883N/R); 20. Spring collar (all except XL 883L and XL 1200X); 21. Spring washer (all except XL 883L and XL 1200X); 22. Fork gaiter (XL 883N); 23. Washer; 24. Lockwasher; 25. Nut; 26. Sliders (RH and LH XL 883L/N and 1200V/C/C ANV/CP/CA/CB); 27. Sliders (RH and LH XL 883R); 28. Sliders (RH and LH XL 1200X)
Disassembly
Drain fork oil
1. See Figure 2-141. Remove tube cap (7) from slider tube (9). Remove O-ring (6) from tube cap.
![](https://motoinstruction.ru/img/harley/12/117758.jpg)
Figure 2-141. Oil seal: 1. Air side; 2. Oil side; 3. Lips
2. Place a pan under the fork. Remove the drain screw and washer (19) from slider. Drain the fork oil.
Fork disassembly
1. See Figure 2-141. Remove spring (5) from slider tube.
2. All except XL 883L and XL 1200X: Remove spring collar (20) and spring washer (21) from slider tube.
3. All except XL 883N: Remove cover (11).
Note. See Figure 2-144. The XL 883N is equipped with fork gaiters (2) instead of metal covers. The lower lip (3) of the gaiter fits into the groove at the upper end of the slider (1). The upper end of the gaiter fits tightly around the slider tube, just below the lower bracket (4).
4. XL 883N: See Figure 2-144. Peel back lower lip (3) of fork gaiter (2) from slider groove and slide fork gaiter up and off end of slider tube.
5. See Figure 2-141. Remove dust seal (12). Compress internal circle clip (13). Remove clip from groove in top of slider bore.
6. Remove screw (18) and washer (17) from bottom of slider.
Note. Since there is little resistance to damper tube (3) rotation within slider tube (9) when removing screw (18), use an air impact wrench for best results.
7. Withdraw slider tube (9) from slider until lower bushing (10) on slider tube contacts upper bushing (1) in slider.
8. Tap out the oil seal (14), the spacer (2) and the upper bushing with the lower bushing on the slider.
9. Remove sleeve (15). Sleeve will be found within slider or on bottom end of damper tube (3).
10. Insert a small diameter rod through opening in bottom of slider tube to remove damper tube assembly.
11. Remove rebound spring (8) from damper tube.
12. Remove damper tube ring(s) (4) from damper tube.
13. Remove lower bushing from damper tube only if replacement is necessary.
Cleaning, inspection and repair
1. Thoroughly clean and inspect all parts. Replace as necessary.
2. See Figure 2-140. Inspect the O-ring (6) for damage, wear or general deterioration. Replace as necessary.
3. Replace all other removed seals.
4. Inspect damper tube ring(s) (4). Replace as necessary.
5. Check dust seal (12) where it contacts slider tube (9). Dust seal should provide continuous contact against slider tube and should not show excessive wear.
6. Check slider tube where it is contacted by seal. Tube surface should be shiny, smooth and free of scoring or abrasions.
7. Verify small hole in lower end of slider tube groove is unobstructed.
Assembly
PART NUMBER | TOOL NAME |
HD-36583 | FORK SEAL AND BUSHING INSTALLATION TOOL |
FASTENER | TORQUE VALUE | |
Fork slider tube fastener: XL | 132-216 | 14.9-24.4 Nm |
Models | in·lbs |
1. See Figure 2-140. If lower bushing (10) was removed, install new lower bushing in groove of slider tube (9). Expand bushing only enough to fit over tube.
2. Install damper tube ring(s) (4) into groove(s) of damper tube (3).
3. Place rebound spring (8) over damper tube (3). Insert damper tube into slider tube.
4. Insert spring (5) into slider tube with the tapered end down. Push damper tube through opening at bottom of slider tube using spring. Place sleeve (15) over end of damper tube.
5. All except XL 1200X: Install spring washer (21) and spring collar (20) into slider tube.
6. Install slider tube assembly into slider. Install screw (18) with washer (17) at bottom of slider. Move slider tube through its full range of travel within slider several times to verify proper component alignment. Then, applying downward force on spring, final tighten screw to 132-216 in·lbs (14.9-24.4 Nm).
Notes:
- See Figure 2-141. Coat the lips (3) of the oil with HARLEY-DAVIDSON SEAL GREASE.
- Apply HARLEY-DAVIDSON SEAL GREASE to the mating surfaces of the dust cover and the oil seal.
7. See Figure 2-140. Place upper bushing (1), spacer (2) (concave side down) and oil seal (14) (lettering side up) over slider tube. Place FORK SEAL AND BUSHING INSTALLATION TOOL (Part No. HD-36583) over slider tube. Install bushing, spacer and seal into slider bore by tapping components downward with the installation tool.
8. Install internal circle clip (13) into groove in top of slider bore.
9. Install dust seal (12) at top of slider.
10. All except XL 883N: Install cover (11).
11. XL 883N: See Figure 2-144. Slide a fork gaiter (2) down each slider tube. Peel back the lower lip (3) and slip over the end of fork slider (1). Fit the lower lip down over groove in upper end of fork slider. Slide the upper end of fork gaiter down as far as possible.
12. All except XL 883L and XL 1200X/V/C/C ANV/CP/CA/CB: See Figure 2-140. Install the drain screw and washer (19) into lower end of slider.
13. Fill the fork tube with fork oil. See 2.19 FRONT FORK: XL MODELS, Fill with Fork Oil.
Fill with fork oil
PART NUMBER | TOOL NAME |
HD-59000-B | OIL LEVEL GAUGE |
1. Position fork tube assembly upright. Compress the assembly fully.
2. Pour approximately 14 fl oz (414 mL) of TYPE "E" HYDRAULIC FORK OIL into fork.
3. Pump the slider tube 8-10 times to expel air and compress the assembly fully.
4. See Figure 2-142. Use the OIL LEVEL GAUGE (Part No. HD-59000-B) to set the fork oil level.
![](https://motoinstruction.ru/img/harley/12/117759.jpg)
Figure 2-142. Oil level gauge: 1. Fork oil level; 2. Tube; 3. Collar; 4. Thumb lock
- a. Adjust the length of the draw off tube to specification (1). Refer to Table 2-21.
- b. Lock the tube (2) to the collar (3) with the thumb lock (4).
- c. Fit the collar to the fork tube.
- d. Draw off the excess oil.
Table 2-21. Fork oil level specifications: XL models
MODEL | in | mm |
XL 883N | 3.11 | 79 |
XL 883L | 4.80 | 122 |
XL 1200X | 6.34 | 161 |
XL 883R/XL1200V | 4.92 | 125 |
XL 1200C/C ANV/CP/CA/CB | 4.72 | 120 |
5. Install spring and other components.
Note. Apply HARLEY-DAVIDSON SEAL GREASE to the O-ring.
6. Install slider tube cap with O-ring. Screw tube cap all the way into slider tube. Finger-tighten only.
Installation
FASTENER | TORQUE VALUE | |
Fork, front, bracket pinch screw | 30-35 ft·lbs | 40.7-47.5 Nm |
Fork slider tube cap | 22-58 ft·lbs | 29.9-78.7 Nm |
Fork, front, bracket pinch screw | 30-35 ft·lbs | 40.7-47.5 Nm |
1. See Figure 2-143. Insert each fork assembly through front fork lower and upper brackets. Position slider tubes so that top of each tube cap extends 0.42-0.50 in (10.7-12.7 mm) (1) above top surface of front fork upper bracket.
![](https://motoinstruction.ru/img/harley/12/117760.jpg)
Figure 2-143. Tube cap extension: 1. 0.42-0.50 in (10.7-12.7 mm); 2. Pinch screw; 3. Tube cap; 4. Pinch screw
2. Tighten front fork lower bracket pinch screws (2) to 30-35 ft·lbs (40.7-47.5 Nm).
3. Now tighten slider tube caps (3) to 22-58 ft·lbs (29.9-78.7 Nm).
4. Tighten front fork upper bracket pinch screws (4) to 30-35 ft·lbs (40.7-47.5 Nm).
5. XL883N: See Figure 2-144. Slide upper end ofeachfork gaiter (2) up until it contacts underside of front fork lower bracket (4).
![](https://motoinstruction.ru/img/harley/12/117761.jpg)
Figure 2-144. Fork gaiter: XL 883N only: 1. Fork slider (2); 2. Fork gaiter (2); 3. Fork gaiter lower lip; 4. Front fork lower bracket
6. Install front fender. See 2.31 FRONT FENDER.
7. Install front wheel assembly and front brake caliper. See 2.5 WHEELS.