Question about 2005 Harley Davidson FLSTC - FLSTCI Heritage Softail Classic

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Switching lower for sliders out to chrome need instructions to assemble and disassemble

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There are two ways to change out the lower sliders on your bike. One, remove the entire fork tube from the steering head and the other, simply remove and replace the lower slider. There really isn't that much difference and I prefer to remove the entire fork tube myself.

First you'll have to get your bike off the gound and stable. Then remove the front wheel, the front brake and the front fender. Remove the windshield, light bar, and nachelle.

Once you get everything out of the way, here's where you can go two different routes. In one, you loosen the clamp bolt at the lower triple tree and remove the top cap of the fork. Spray a bit of penetrating oil around the fork tube in the lower tree and start working the tube out. Once the tube is out, remove the top plug and spring. Turn the fork tube upside down and empty the oil out of it and remove the spring. Look at the spring. It's tapered on one end, make sure you put this end in first when you reassemble the tube. With the fork tube upside down, look at the bottom end of the slider where the axle goes through. You'll see a single 8mm bolt. Remove this bolt and the slider will come off.

In the other method, you do it the same way except you don't remove the fork tube from the triple. You remove the top cap and the tube plug. Remove the drain plug and drain the oil out of the fork tube. Remove the screw and remove the lower slider. It is quite a bit messier as all the oil is not out of the slider when you take it off.

When you reassemble, make sure you use the proper quantity of oil in each leg. You will see a "wet" and "dry" measurement. Use the "dry" measurement since you disassembled the fork. I do not have the quantity of oil you should use for your model. A dealer should be able to tell you.

Good Luck
Steve

Posted on Nov 14, 2010

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Posted on Jan 02, 2017

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To change the oil or to rebuild a 2007 DYNA front fork FIRST raise and support the motorcycle so that the front end is off the floor and the forks are fully extended, remove the brake caliper and the front wheel, remove the front fender, loosen the pinch bolt screws, do not remove the tube caps, slide the fork sides downward clear of the fork brackets, repeat the procedure for the opposite fork tube and slider assembly.

To disassemble a 2007 DYNA front fork clamp the fork tube and slider assembly in a fork tube holder tool mounted horizontally in a vise, use a 12mm Allen wrench is needed to loosen but do not remove the seat pipe screw, while the internal components are still under tension and less prone to rotate, on the right fork tube and slider assembly, remove the axle holder to access the seat pipe screw, remove the fork tube cap and its o-ring, remove the long spring collar, remove the fork assembly from the fork tube holder tool and invert it over a suitable container to catch the fork oil and allowing thefork to drain, extend and retract the slider several times to push oil out of the internal fork components, the washer, and the spring will fall out of fork tube. THEN clamp the fork tube in the fork tube holder tool, remove the slider cover from the slider by inserting a brass drift into the notch in the slider and lightly tapping the cover loose, compress the stopper ring and remove the stopper ring from the groove in the top of the slider bore, Do not remove slider tube caps without relieving the spring preload or the caps and springs may fly out. THEN remove the seat pipe screw and its washer from the bottom of the slider and retain them for reuse, withdraw the slider from the fork tube until the bushing guide contacts the bushing on the fork tube (the bushing guide is a slight interference fit in the slider), then using the slider as a slide hammer, hit the bushing with the bushing guide with a quick continuous stroke until the slider is pulled free from the fork tube, drain the slider and allow the stop oil lock piece to fall free. (If you are only changing the oil or replacing the slider the remaining parts can be left assembled and the fork re-assembled) If it is still attached to the seat pipe remove the stop oil lock piece from the lower end of the seat pipe, remove the seat pipe piston and the ring assembly, remove the rebound spring, remove the oil seal, remove the seal spacer, and remove the bushing guide. Repeat the foregoing procedure for the opposite fork tube and slider assembly.

Thoroughly clean and inspect each part and if and as necessary replace any corroded, worn, bent, broken or otherwise damaged parts, inspect the fork tube bushing and the slider guide bushing and replace if and as required, always replace all oil seals and all o-rings, check the dust cover where it rubs on the fork tube (it should have a good and continuous seal and not show excessive wear, check the fork tube where it rubs on dust the cover and the tube should show a bright, shiny surface, free of scoring or abrasions, if any spring(s) is/are broken they must be replaced, if a fork tube or slider is bent or damaged it must also be replaced now, replace all other worn or damaged components if and as necessary.

To assemble a 2007 DYNA fork FIRST insert the seat pipe assembly with the spring into the slider tube, slide the bushing guide down to the bushing on the fork tube, follow it with the spacer, the oil seal, the stopper ring, the dust shield and the slider cover, install the fork tube into the fork tube holder tool, fit the lower stop onto the seat pipe, slide the seat pipe back into the fork tube until the seat pipe is centered in the tube, gently install the slider assembly onto the slider tube and the bushing, thread the seat pipe screw and washer into the seat pipe through the bottom of the slider assembly, draw the fastener into the seat pipe but do not tighten it at this time, verify the proper action of the fork by moving the slider up and down the fork tube, locate the appropriate fork seal driver over the fork tube in front of the oil seal with the fork seal chamfered lips facing the oil in the fork, in the following order assemble thetop oil seal, the spacer and the bushing guide into the slider bore, install the stopper ring into its groove above the oil seal, push the dust seal against the oil seal and stopper ring, rotate the slider cover to match any removal burrs to the notch in the slider and snap the slider cover into place. THEN operate the slider through its full range of travel several times to verify alignment and proper smooth operation, then pulling down on the slide to apply downward force on the rebound spring, tighten the seat pipe screw to 106-159 in-lbs (12-18 Nm), vertically re-position the fork tube into the fork tube holder tool and with the slider tube compressed, fill the fork with Harley-Davidson TYPE E FORK OIL until it is approximately the amount specified below for the type or motorcycle and fork that it is.

a. FXDWG- approximately 29.6 oz (875 cc) and distance from the top of the fork tube = 4.4 in (112 mm); and
b. All other Dyna models- approximately 26.6 oz (787 cc) and distance from the top of the fork tube = 4.3 in (110 mm)
THEN slowly pump the slider 8 to 10 times to remove air from the fork assembly and fully compress the slider to properly measure the oil level which is measured from the top of the fork tube, with the spacer and the spring removed and the fork fully compressed, then using an appropriate oil level gauge tool adjust the oil level to appropriate level for the fork type and model, pull out the slider and install the spring in the fork tube with the tightly wound end at the bottom, install the washer and the spring collar, carefully to avoid cross threading, install the fork tube cap with a new o-ring and tighten it to 16-43 ft-lbs (22-58 Nm). Repeat the process for the other fork tube and slider assembly.

To install the fork in a 2007 DYNA FIRST insert the fork tube and the slider assemblies up through the lower triple clamp and the upper triple clamp so that the fork tubes will protrude above the upper triple clamp 0.450-0.500 in. (11.4-12.7 mm) with the measurement taken at the midpoint of the fork tube between the top surface of the triple clamp and the top of the fork cap and when properly positioned tighten the pinch bolts to 30-35 ft-lbs (41- 48 Nm), install the front fender and bracket, install the front brake caliper(s), install the front wheel and align the wheel to the forks.

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1 Answer

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Unless you've had your front fork assembly serviced recently, I'd guess you've got blown oil seals in the top of the sliders on your forks. If someone serviced your forks lately, they may have put in too much oil and blown the seals. You'll have to drain the forks, disassemble the fork tube from the lower slider and replace the seal in each leaking tube. Refill the fork tube with the designated about of oil for a "dry" refill. Use this figure because the fork tube was disassembled. When you simply drain the forks without a disassembly, you cannot get all the oil out and the refill quantity is less.

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1 Answer

I am putting chrome lowers and the and chrome fork covers on my wifes 2005 deluxe, my first fork work, what is the nachelle, do I need to remove the forks, will that access the attaching hardware on the...


The nachelle is the polished or chromed cover around the headlight and the triple trees of the front end. I think the "nostalgia" model has the early model "tins" like on a fatboy. This is considered the nachelle.

Now, if you installing "covers" which are thin chrome plated alumnium or steel overlays to the forks, I would think they would be made so you could install them without disassembly of the forks. But, if you're installing "chromed lower sliders", you'll have to remove and disassemble the fork tubes one at the time to swap out the slider on each tube.

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Jack the bike up off the ground. Remove the front wheel and front fender. Loosen the pinch bolt in the lower triple tree and take the nut off the top of the upper tube at the upper tree. The fork assembly should slide down and out of the triple trees. Invert the fork tube to pour out the oil and remove the spring. Look on the very end of the lower slider where there is an 8mm bolt. Take the bolt out and the lower slider comes off the upper tube. Reassembly is the reverse of disassembly. Add the correct amount of oil for a "dry" rebuild.

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Ignition Switch REMOVAL & INSTALLATION 1982–91 Vehicles The switch is located on the steering column and is completely inaccessible without first lowering the steering column. The switch is actuated by a rod and rack assembly. A gear on the end of the lock cylinder engages the toothed upper end of the rod.
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  2. Put the switch in the OFF-UNLOCKED position. With the cylinder removed, the rod is in OFF-UNLOCKED position when it is in the next to the uppermost detent.
  3. Unfasten the two switch screws and remove the switch assembly. Fig. 1: Removal and installation of the ignition switch and related steering column components — 1990 vehicle shown 87958059.gif
    Fig. 2: Exploded view of a steering column including the ignition switch — 1990 vehicle with standard column shown 87958060.gif
    Fig. 3: Exploded view of the steering column including the ignition switch — 1990 vehicle with tilt column shown 87958061.gif
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GM Buick/Oldsmobile/Pontiac/Full-Size 1975-1990
Repair Guide - Ignition Switch

CAUTION Do not attempt any service on the steering wheel, column or instrument panel on Buick and Oldsmobile models equipped with an air bag. Service on these models should only be performed by a professional technician.

REMOVAL & INSTALLATION
  1. Turn the steering wheel so the vehicle's wheels are in the straight ahead position. Turn the key to the LOCK position.
  2. Disconnect the negative battery cable.
  3. Remove the column to instrument panel trim plates and attaching nuts.
  4. Lower the column and disconnect the shift indicator cable.
  5. Disconnect the ignition and dimmer switch connectors.
  6. Remove the switch attaching screws and remove the switch.
To install:
  1. Move the actuator rod hole in the switch to the lock position.
  2. Install the switch with the rod in the hole. Adjust the switch as follows:
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    2. 1989 and 1990 - Place a 3/32 in. drill bit in the hole on the switch to lock the switch into position. Move the switch slider to the extreme left position then move the slider 1 detent to the left LOCK position.

  3. Position and reassemble the steering column in reverse of the disassembly procedure.
I hope helped with this (remember rated this help) Good luck.

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2 Answers

I am replacing my OEM lower fork sliders with Chrome ones. How much fork oil is required and do I need to replace the seals or anything else? My bike is a 2005 Softail Deluxe.


The best way to do this is to get a clean containe and carefully drain the fork oil into it and measure how much came out nad replace the same amount.
I use a measuring cup from an automotive paint store.
Your old seals should be good but give them a good visual check first.

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1 Answer

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See Figure 1


0900c15280047a11.jpg enlarge_icon.gifenlarge_tooltip.gif Fig. Fig. 1: Ignition switch assembly
If equipped with an air bag system, make certain to follow the recommended disarming procedure before, and rearming procedure after, repairs.
  1. Disconnect the negative battery cable and disable the air bag system, if equipped.
  2. Remove the column to instrument panel trim plates and attaching nuts.
  3. Lower the steering column and disconnect the shift indicator cable.
  4. Disconnect the ignition and dimmer switch wire connectors.

The steering column must be supported at all times to prevent damage.
  1. Remove the switch attaching screws and remove the dimmer switch followed by the ignition switch.

To install:
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  2. Move the actuator rod hole in the switch to the LOCK position.
  3. Install the switch with the rod in the hole. Adjust the ignition switch as follows:
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  4. Position and reassemble the steering column in reverse of the disassembly following the proper coil centering procedure. Enable the air bag system, if equipped, as follows:
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