Question about 2004 Harley Davidson FXSTD - FXSTDI Softail Deuce

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Front fork dust cover removal 2004 fxstd - 2004 Harley Davidson FXSTD - FXSTDI Softail Deuce

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Posted on Jul 25, 2013


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Replacing front brake pads 2001FXST

Front Brake Caliper: All But FLSTS/FXSTS

Remove the front master cylinder reservoir cap to be able to check the fluid level as the caliper pistons are pushed back into the caliper because the fluid level may rise more than the 1/8 in. (3.2 mm) from the top level and you may have to remove some excess fluid if it does so. THEN loosen but do not remove both pad pins with a 12 point one quarter inch socket. THEN remove both metric caliper mounting bolts and remove the caliper from the front forks and brake disc and pry the pads back to force all four caliper pistons into their bores. THEN once the pistons have been retracted, remove the pad pins and the brake pads.

Although the front and rear brake calipers except FXSTD models, use the same exact brake pad set the FXSTD does not and the FXSTD rear pads have a vertical slot cut into the pads. Be sure NOT to substitute front and/or rear brake pads for the other on these bikes. On the right side of the vehicle the pad with the two tabs installs on the inboard side of the caliper and on the left side of the vehicle, the pad with the two tabs installs on the outboard side of the caliper.

THEN install new pads into the caliper noting that the curved portion of the pad faces to the rear of the bike, and loosely install the pad pins until you hear an audible click from them. THEN re-attach the caliper to front fork, place the caliper over the brake disc with the bleeder valve facing upwards, loosely install the long caliper mounting bolt into the top hole on the fork leg, install the short mounting bolt into the bottom hole on the fork le, tighten the bottom mounting bolt to 28-38 ft-lbs (38.51.5 Nm) and final tighten the top mounting bolt also to 28-38 ft-lbs (38.51.5 Nm) and final tighten the two pad pins to 180-200 in-lbs (20.3-22.6 Nm).

THEN and whenever new pads are installed, before moving the bike pump the brakes until brake fluid pushes the caliper pistons and the pads out and verify that the pads are against the brake disc and then rotate the wheel to ensure there is not any excessive drag between the pads and the disc, check for proper fluid level in the reservoir and if necessary top it up with DOT 5 Silicone base brake fluid only, install the reservoir cover and tighten its screws to 6-8 in-lbs (0.7-0.9 Nm).

THEN and whenever any work has been done on brakes always test the brakes at low speed before operating on a roadway or at higher speeds. THEN test brake system light and if during the road test the brakes feel spongy at all bleed the system and after obtaining a hard lever or pedal road test the bike again.

Oct 04, 2014 | Cars & Trucks

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How to replace fork seals 2007 fatboy

To replace the front fork oil first support the motorcycle so the front end is off the floor and the forks are fully extended. Remember that the FLSTC and FLSTF models have a preloaded fork spring and that the fork tube plug is under spring pressure.Then you remove the fork tube caps. And then you drain the fork oil. ON FXSTD models, your remove the drain screws and washers from each fork and drain the fork oil this way. ON ALL MODELS EXCEPT the FXSTD, remove and discard the drain screws and washers from each fork and drain the fork oil and then you install new drain screws and washers. ON FXSTD models, apply LOCTITE THREADLOCKER 243 (blue) to the drain screws and tighten them to 12-18 inlbs (1.4-2.0 Nm). ON ALL MODELS EXCEPT FXSTD, tighten the drain screws to 52-78 in-lbs (5.9-8.9 Nm).THEN fill the fork with Harley-Davidson TYPE E FORK OIL (Part No. HD-99884-80).Either by installing oz or cc's of fluid if the forks were left in the frame or by measuring the amount of oil in the tubes in inches or mm if the forks were removed from the frame and disassembled. In the latter case the oil level is measured from the top of the fork tube with the spring removed and the fork fully compressed.

MODELs FLSTC, FLSTN use 13.4 OZ 395 cc4.41 inches 112.0 mm
MODEL FLSTF uses 13.4 OZ 397 cc5.04 inches128.0 mm
MODELs FXST, FXSTB, FXSTC use 12.5 OZ370 cc 6.69 inches170.0 mm
MODEL FXSTD uses 11.6 OZ343 cc 7.48 inches190.0 mm

FINALLY tighten the fork tube caps to 40-60 ft-lbs (54.2-81.3 Nm).

Jul 10, 2014 | 1993 Harley Davidson FLSTF Fat boy

1 Answer

Front forks allen

Hi Anonymous, 1/4" or 5/16". Have nice day.

Aug 17, 2013 | 2004 Harley Davidson FXSTD - FXSTDI...

1 Answer

Front fork dust cover removal

Hi Jim, usually just a small tap in opposing sides with a small wooden or soft plastic tool from the bottom will release it from the rubber dust shield. Good luck

Jul 24, 2013 | 2004 Harley Davidson FXSTD - FXSTDI...

1 Answer

Rear brake caliper leaks

Hi Anonymous, it's a dust cover for the bleeder valve, remove it and tighten the valve some more the reinstall the rubber dust cover. Have nice day.

Sep 10, 2012 | 2004 Harley Davidson FXSTD - FXSTDI...

1 Answer

My deuce has 8in over forks . can i cut these forks succesfully.

Not unless you have the proper tools to rethread the inside of the new "top" of the tubes. You need to purchase new fork tubes and swap them out on your lower sliders.

Good Luck

Mar 20, 2011 | 2004 Harley Davidson FXSTD - FXSTDI...

1 Answer

How to replace the fork seals on a 2003 harley davidson fatboy

If you ask this question YOU should not be doing it! but your *** on the seat not mine.
Remove ...........front wheel, front fender,top fork cap and loosen lower triple clamp bolts under head light cover, forks are now out!
Remove 6mm bolt at the bottom of the fork leg and drain oil,remove dust seal and wire clip, now remove the upper fork nut (the spring will jump out at you).Pull the leg and tube away from each other, the old seal will stay on the tube..clean and reassemble driving NEW seal down into place with wire clip.....refill with oil

Mar 31, 2010 | 2003 Harley Davidson FLSTFI Fat Boy

1 Answer

Seals blown on front shocks

to remove seals you will need to remove each fork leg from the bike,i put the bike on the centre stand and jack under the motor to get the front wheel off the ground,after you remove the fork leg,remove the dust cover(if fitted),remove the circlip holding the old seal,you may have to stab through the old seal with a screwdriver to remove the seal from inside the leg(be carefull not to damage the chrome on the fork leg),clean around the surfaces and install the new seal making sure it goes back in dead square,refit the circlip,then refit the dust cover,replace fork tube back in bike and top up with new oil,most bikes take between 300 to 500cc of oil,but check with your local shop as all bikes are different,and you can adjust the amount of rebound damping by varying the amount of oil you put back in,..sounds complicated but quite an easy job..hope this helps

Jul 04, 2009 | 1995 Suzuki GS 500 E

1 Answer


dont if you feel you must remember it will raise the front of the bike up or you will have to cut the neck reweld change handle bars to achieve a ridable geometery

Jun 25, 2009 | 2004 Harley Davidson FXSTD - FXSTDI...

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