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Loosen and remove the fork cap bolt sub-tank from the outer tube and slowly slide down the outer tube : Front fork top cap wrench Clamping the outer tube too tight can damage it which will affect riding stability. Do not clamp the outer tube too tight. Place a drain pan under the front fork and drain fork oil. NTE: Face the oil hole A on the sub-tank downward.

Protect the axle holder surface using a rag. Loosen the center bolt 3 completely with a 21 mm socket wrench. Clamping the axle holder too tight can damage it which will affect riding stability. Do not clamp the axle holder too tight.

Compress the outer tube by hands and install the conrod holder special tool between the axle holder bottom 2 and locknut : Conrod holder Hold the locknut with a wrench and remove the center bolt. Do not remove the locknut 4 from the inner rod. Loosen the fork cap bolt 1 sub-tank and remove the sub-tank 5 along with the damper rod assembly 6.

Disassembling the damper rod assembly can lead to trouble. Do not disassemble the damper rod assembly. Do not separate the sub-tank and damper rod assembly.

Scratches on the inner tube could cause oil leaks. Avoid scratching when removing. Guide bushing 1 Seal retainer 2 il seal 3 Stopper ring 4 Dust seal 5 Clamp the bottom flat part of the sub-tank with a vise.

Do not clamp the sub-tank too tight. Loosen the compression damper unit. NTE: Slowly compress the inner rod until it stops so that the compression damper unit can be removed easily.

Drain the fork oil from the damper rod assembly by moving the inner rod several strokes. If it is damaged, replace it with a new one. Disassembling the compression damper unit can lead to trouble. Do not disassemble the compression damper unit. If it has scratches, replace it with a new one. Inspect the outer tube for dent. If it is dented all the way to the inner side, replace it with a new one. Measure the inner tube runout using the V-blocks and dial gauge.

Inner tube runout Service Limit: 0. If it has scratches or is bent, replace it with a new one. Service Limit: mm If they are worn or damaged, replace them with new ones. Inspect the metal particles on the teflon coating metals. If they are not clean, clean them with a nylon brush and fork oil. Cover the inner tube with a plastic film. Install the following parts to the inner tube: New dust seal 1 Stopper ring 2 New oil seal 3 Scratches on the oil seal lip can cause oil leaks.

When installing the seals, place a plastic film over the bushing attachment groove and edges of the inner tube to avoid damaging the seals lip. NTE: The side of the oil seal that has a mark should face the dust seal.

Clean the parts and keep them free from dust. NTE: Inspect the bushings for burrs. If there is a burr, remove it with a knife, taking care not to peel off the teflon coating. If the bushings have a large crack or excessive play after installing them, replace them with new ones. Insert the inner tube into the outer tube. Attach the dust seal 1. NTE: After attaching the dust seal, make sure that there are no cracks around the circumference of the seal.

Cracks could allow water, mud and the like to enter and cause an oil leak. Use of grease as a substitute fork oil when installing the oil seal can result in an oil leak. Applying grease to the dust seal and oil seal can cause dirt to accumulate and damage the dust seal lip and oil seal lip. Use only a thin coat of fork oil on the oil seal. With the damper rod in fully extended position, pour the specified amount of fork oil.

Fork oil quantity Inside the damper rod : ml 6. With the damper rod held immovable in fully extended position, gently install the compression damper unit to the sub-tank.

Clamp the bottom flat part of the sub-tank with a vise. Tighten the compression damper unit to the specified torque. Compression damper unit: 30 N m 3. Tighten the locknut by hand completely.

Protect the inner rod end with a rag when compressing the damper rod. NTE: Set the compression damper setting to the softest. With the damper rod in horizontal position, move the inner rod by hand to inspect it if operating smoothly. Completely wipe off the fork oil from the spring and damper rod assembly.

Insert the spring and damper rod assembly into the fork. Protect the axle holder with a rag when using a vise. Compress the outer tube by hands and install the conrod holder special tool between the axle holder bottom and locknut : Conrod holder Insert the push rod into the inner rod.

Insert the shaped projection of center bolt into the push rod. Slowly turn the center bolt clockwise until resistance is felt and check the clearance between the locknut and center bolt to provide more than 1 mm 0. Tighten the center bolt to the specified torque. Center bolt: 70 N m 7. Check that the air valve A is positioned at the front. Tighten the fork lower clamp bolts to the specified torque. Fork lower clamp bolt: 23 N m 2.

Fork upper clamp bolt: 23 N m 2. D-ZS Install the front wheel. D-ZS Check that the front fork protectors move smoothly. If not, loosen and adjust the protector guide. Turn the adjuster screw counterclockwise.

For E, 28, 33 Loosen the axel nut 1. Loosen the locknuts 2 and adjust the drive chain slack to the specification by turning the adjusters 3.

Make sure that the right and left adjuster plates 4 are at the same position on scales 5. With the adjusters 3 held in position, tighten the locknuts 2. Push the adjuster plates 4 to the adjusters 3 and tighten the axel nut 1. Axel nut: N m NTE: After installing the rear axel nut, insert a new cotter pin into the rear axel. For E, 28, 33 Soft Hard. Set the brake hose in front of the throttle cables.

Set the brake hose outside of the front fork. Set the brake hose in front of the clutch cable. Clump the upper difference portion in brake hose diameter. Set the brake hose guide outside of the turn signal bracket. Insert the reservior hose until dead end. For exploded diagram and part number information, refer to the Spare Parts Catalog available on our website at www.

Information contained in this publication is subject to change at anytime. Road King models use the conventional. For this reason, technical data, equipment and design are subject to change without notice.

It is a document to be used in conjunction. Any attempt to copy or resell is a direct violation of our copyright. All violators will be prosecuted. Information contained in this publication is subject.

For complete service. Contact your local distributor or visit the. When doing any repair work, especially in the engine compartment,. One possible cause is wheel. Slide the new steering column shaft through the steering column from the driver compartment. Push the column shaft through the steering column until the machined end is out past the column lower bushing.

After replacing brake pads and before moving vehicle, depress brake pedal several times firmly to properly. There have been modifications to the internal. Register this product.

Front axle components, overview General Information Load bearing components and parts of the suspension must not be welded or straightened. Vehicles without drive axle must not be moved,. Make Make. Model Model. The original Haynes Repair Manual - Based on a complete stripdown and rebuild of a vehicle.

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