Content      ..     9      10      11      12     ..

Harley Davidson 2006 Sportster XLH MODELS. Service Manual - page 11

HOME

8.

See Figure 2-112. See Figure 2-111. Using an open-end

10439

wrench, unscrew mounting bracket bolt pin (5) from cali-

4

per mounting bracket (1). Lift brake caliper (6) straight

3

up, away from brake disc and caliper bracket.

10618

1

2

1.

Brake caliper

2.

Brake pad pin

3.

Brake pad friction material

4.

Brake pad backing plate

Figure 2-112. Removing Rear Caliper Bolt Pin

Figure 2-113. Preparing Caliper for Piston Removal

4. See Figure

2-114. Gently apply low pressure com-

DISASSEMBLY

pressed air to banjo bolt hole (3) to force piston from cal-

iper bore.

1.

See Figure

2-111. Remove pad spring

(2). Do not

5. Remove brake pad pin and brake pad from caliper.

remove bleeder valve (12) at this time.

6. See Figure 2-111. Remove piston (16) from caliper bore

2.

See Figure 2-113. Install a discarded brake pad in the

by hand. If necessary, gently wiggle piston to completely

caliper with the backing plate (4) facing the piston. Posi-

remove.

tion the brake pad so the friction material (3) is against

the back of the caliper, as shown.

8989

3.

Loosely install brake pad pin (2) to hold brake pad in

3

place.

1

1WARNING

Compressed air can pierce the skin and flying debris

from compressed air could cause serious eye injury.

Wear safety glasses when working with compressed air.

Never use your hand to check for air leaks or to deter-

mine air flow rates. (00061a)

CAUTION

4

2

Be careful not to damage banjo bolt sealing surface or

1.

Low pressure air nozzle

threads of banjo bolt hole in brake caliper. It is recom-

2.

Brake caliper

mended that you use an air nozzle with a rubber tip to

3.

Banjo bolt hole

perform the next step in this procedure.

4.

Brake pad

Figure 2-114. Removing Piston

1CAUTION

In the next step, the piston will be forced out of its bore

and up against the brake pad backing plate. Keep fingers

away from this area. Failure to do so could result in seri-

ous injury.

2-70

2006 Sportster: Chassis

HOME

1. Clean all metal parts with denatured alcohol.

CAUTION

2. See Figure 2-111. Wipe old lubrication from inside of cal-

iper pin boot (3) and caliper bushing boot (8) with a

A damaged piston bore will leak when reassembled. Do

clean, lint free cloth.

not use metal objects to remove or install components in

piston bore. Prevent damage to piston, seal and bore by

3. Clean all other rubber parts with HARLEY-DAVIDSON

only using a wooden toothpick when servicing caliper.

D.O.T. 5 BRAKE FLUID. Do not contaminate with mineral

oil or other solvents. Wipe parts dry with a clean, lint free

7.

See Figure 2-115. Using a wooden toothpick (1), remove

cloth.

dust seal (2) and piston seal (3) from caliper bore. Dis-

card seals.

1WARNING

8.

See Figure 2-111. If necessary, remove bleeder valve

(12).

Compressed air can pierce the skin and flying debris

from compressed air could cause serious eye injury.

Wear safety glasses when working with compressed air.

8991

Never use your hand to check for air leaks or to deter-

mine air flow rates. (00061a)

1

4. Blow out drilled passages and piston bore with low pres-

sure compressed air from a clean air supply. Do not use

2

a wire or similar instrument to clean drilled passages.

5. Carefully inspect all components. Replace any parts that

appear damaged or worn.

a. Check piston (16) for pitting, scratching or corrosion

on outside surfaces.

b. Inspect caliper (6) piston bore. Do not hone bore. If

bore shows pitting or corrosion, replace caliper.

3

c. Inspect pad pin (10) for grooving and wear. Measure

the pad pin diameter in an unworn area, and then in

the area of any grooving or wear. If wear is more

1.

Wooden toothpick

than 0.011 in. (0.28 mm), replace pad pin.

2.

Dust seal

3.

Piston seal

d. Inspect caliper bolt pin (7). If damaged or exces-

sively worn, replace bolt pin.

Figure 2-115. Caliper Seals

e. Inspect caliper bushing boot and caliper pin boot. If

worn or damaged, replace.

CLEANING, INSPECTION AND

f.

Always replace all seals after disassembly.

REPAIR

1

WARNING

Always replace brake pads in complete sets for correct

1WARNING

and safe brake operation. Improper brake operation

could result in death or serious injury. (00111a)

Always use denatured alcohol to clean metal brake sys-

tem components and HARLEY-DAVIDSON D.O.T.

5

6. Inspect brake pads (13) and brake disc. Replace if nec-

BRAKE FLUID to clean rubber brake system compo-

essary.

nents. Do not use mineral-base cleaning solvents, such

a. See 1.10 BRAKE PADS AND DISCS for specifica-

as gasoline or paint thinner. Use of mineral-base sol-

tions.

vents causes deterioration of rubber parts that continues

b. See REAR WHEEL under 2.4 WHEELS for brake

after assembly. This may result in improper brake opera-

disc replacement procedure.

tion which could result in death or serious injury.

2006 Sportster: Chassis

2-71

HOME

3. Carefully insert piston by hand, nose radius first (see Fig-

ASSEMBLY

ure 2-116.), into caliper bore. If installation shows resis-

tance, remove piston and check that seals are properly

installed and fully seated in grooves.

CAUTION

4. See Figure 2-111. Install bleeder valve (12) on caliper

Use ONLY KS62F assembly grease for lubrication. Use of

housing if removed. Do not tighten bleeder valve at this

D.O.T. 5 brake fluid will result in increased brake pedal

time.

travel.

5. See Figure 2-117. Place caliper housing on workbench

1.

Lubricate the following parts prior to assembly using a

as shown. Install pad spring in channel. Press firmly into

light coat of KS62F assembly grease from the service

place.

parts kit. All other surfaces must be dry for assembly.

a. Nose radius of piston. See Figure 2-116.

8964

b. All surfaces of piston seal and dust seal.

10438

Figure 2-117. Rear Caliper Pad Spring

Figure 2-116. Piston Nose Radius

CAUTION

A damaged piston bore will leak when reassembled. Do

not use metal objects to remove or install components in

piston bore. Prevent damage to bore by only using a

wooden toothpick when servicing caliper.

2.

See Figure 2-115. Install a new piston seal (3) and a

new dust seal (2) into piston bore.

2-72

2006 Sportster: Chassis

HOME

LUBRICATING REAR CALIPER

10348

1

BOLT PINS AND BOOTS

2

4

6

1.

See Figure 2-118. Apply approximately 0.4 g of G40M

BRAKE GREASE inside caliper bushing boot (3) and cal-

iper pin boot (4).

2.

See Figure 2-119. Apply G40M BRAKE GREASE inside

boot lip (8) to prevent sticking between boots (3, 4) and

bolt pins (5, 6).

3

3.

Insert mounting bracket bolt pin (6) into caliper bushing

boot (3).

5

10350

10347

7

1

3

2

6

5

8

3

6

4

1.

Rear brake caliper

1.

Rear brake caliper

2.

Caliper mounting bracket

2.

Caliper mounting bracket

3.

Caliper bushing boot

3.

Caliper bushing boot

4.

Caliper pin boot

4.

Caliper pin boot

5.

Bolt pin (caliper)

5.

Bolt pin (caliper)

6.

Bolt pin (mounting bracket)

6.

Bolt pin (mounting bracket)

7.

Tapered shoulder

8.

Boot lip

Figure 2-118. Lubricating Caliper Boots and Pins

Figure 2-119. Assembling Rear Brake

Caliper to Mounting Bracket

2006 Sportster: Chassis

2-73

HOME

INSTALLATION

10618

1.

See Figure 2-120. Before installing caliper, make sure

that retainer bracket is properly installed on mounting

bracket.

10435

Figure 2-121. Installing Rear Caliper Bolt Pin

10624

2

Figure 2-120. Retainer Bracket

2.

See Figure 2-111. Apply a small amount of LOCTITE

272 THREADLOCKER to threads of mounting bracket

5

bolt pin (5).

1

3.

Place rear caliper assembly (6) onto mounting bracket

(1).

4.

See Figure 2-121. Using an open end wrench, thread

mounting bracket bolt pin into caliper mounting bracket.

Tighten to 87-130 in-lbs (9.8-14.7 Nm).

6

5.

See Figure 2-111. Apply a small amount of LOCTITE

4

3

272 THREADLOCKER to threads of caliper bolt pin (7).

6.

Slide caliper bolt pin through front mounting hole in cali-

1.

Banjo bolt

per (6). Carefully insert bolt pin shaft into caliper pin boot

2.

Washer (2)

(3) in mounting bracket (1). Screw bolt pin into caliper

3.

Rear brake line

and tighten to 15-18 ft-lbs (20.4-24.6 Nm).

4.

Brake caliper

5.

Caliper mounting bracket

NOTE

6.

Damper

Brake caliper housing has a positive stop for banjo fitting.

When tightening banjo bolt into brake caliper in the next step,

Figure 2-122. Rear Caliper Assembly

rotate banjo fitting clockwise until it contacts positive stop.

7.

See Figure 2-122. Position a new washer (2) on each

side of hydraulic brake line (3) banjo fitting. Insert banjo

bolt (1) through washers and fitting. Thread bolt into cali-

per housing. Tighten to 20-25 ft-lbs (27.1-33.9 Nm).

2-74

2006 Sportster: Chassis

HOME

NOTE

10. See Figure 2-111. Install pad pin plug (9). Tighten to 18-

The rear brake caliper does NOT use the same exact brake

25 in-lbs (2.0-2.9 Nm).

pad set as the front left and front right (not present on all vehi-

cles) calipers.

1WARNING

8.

See Figure 2-123. Insert brake pads (1) into caliper with

Direct contact of D.O.T. 5 brake fluid with eyes can cause

friction material on pad facing brake disc. Curved portion

eye irritation, swelling, and redness. Avoid eye contact.

of pad fits into recessed area of caliper. Make sure brake

In case of eye contact flush with large amounts of water

pad front mounting tab (2) fits into slot (5) in caliper

and get medical attention. Swallowing large amounts of

mounting bracket (4).

D.O.T. 5 brake fluid can cause digestive discomfort. If

swallowed, obtain medical attention. Use in well venti-

lated area. KEEP OUT OF REACH OF CHILDREN.

8963

2

3

(00144a)

3

NOTES

● Rear brake master cylinder reservoir must be in a level

position when filling and checking fluid level.

● See Figure 2-124. Reservoir cover (2) may be removed

from rear brake master cylinder reservoir (1) to more

1

1

easily verify fluid level in reservoir.

11. Position motorcycle upright (not resting on jiffy stand).

10346

See Figure 2-124. Remove rear brake master cylinder

2

reservoir cap

(5). Add HARLEY-DAVIDSON D.O.T. 5

4

BRAKE FLUID to reservoir until fluid reaches upper fluid

level (3). Do not overfill reservoir. Do not reuse brake

fluid.

10335

3

5

1.

Brake pad

2.

Front mounting tab

4

3.

Pad pin hole

5

4.

Rear caliper mounting bracket

2

5.

Slot

10333

Figure 2-123. Installing Rear Brake Pads

3

9.

See Figure 2-111. Press brake pads (15) tightly up

against pad spring (2) and install pad pin (10). Tighten to

4

131-173 in-lbs (14.8-19.6 Nm).

NOTES

1

If pad pin does not fit, check the following:

● You are using a set of pads, not two identical pads.

● Pad spring orientation must match Figure 2-117.

1. Rear brake master cylinder reservoir

● See Figure 2-123. Pad front mounting tabs (2) must be

2. Reservoir cover

fully seated in mounting bracket slot (5).

3. Upper fluid level

4. Lower fluid level

● Pads must be pushed tight up against pad spring before

5. Reservoir cap

pad pin is installed.

Figure 2-124. Rear Brake Master Cylinder Reservoir

2006 Sportster: Chassis

2-75

HOME

BRAKE LINES

2.16

FRONT BRAKE LINE

Removal

1. See Figure 2-125. See Figure 2-126. Remove bleeder

nipple cap (2) from bleeder valve (3) on front brake cali-

1WARNING

per (1). Install end of a length of 5/16 in. (7.9 mm) I.D.

clear plastic tubing over caliper bleeder valve (3), while

Direct contact of D.O.T. 5 brake fluid with eyes can cause

placing free end in a suitable container. Open bleeder

eye irritation, swelling, and redness. Avoid eye contact.

valve about 1/2 turn. Pump brake hand lever to drain

In case of eye contact flush with large amounts of water

brake fluid. Close bleeder valve.

and get medical attention. Swallowing large amounts of

D.O.T. 5 brake fluid can cause digestive discomfort. If

2. See Figure 2-127. Remove screw (5) to detach brake

swallowed, obtain medical attention. Use in well venti-

line clamp (4) from front fork upper bracket (right side).

lated area. KEEP OUT OF REACH OF CHILDREN.

(00144a)

x0417a2x

1

1

10340

2

3

3

5

4

6

9

2

1

10

11

1.

Front brake caliper

2.

Bleeder nipple cap

3.

Bleeder valve

Figure 2-125. Front Caliper Bleeder Valve

7

8

8

x0419a2x

2

2

1

1

1. Washer (XL 883R/XL 1200R: 6, all others: 4)

2. Banjo bolt (2)

3. Banjo bolt (XL 883R/XL 1200R only)

4. Clamp

5. Screw

6. Hydraulic brake line (all except XL 883R/XL

Figure 2-126. Bleeding Hydraulic System

1200R)

7. Clamp (all except XL 883R/XL 1200R)

8. Screw with captive washer

9. Clamp (XL 883R/XL 1200R only)

10. Hydraulic brake line (XL 883R/XL 1200R only)

11. Brake line manifold (XL 883R/XL 1200R only)

Figure 2-127. Front Brake Line

2006 Sportster: Chassis

2-77

HOME

3.

Detach brake line from stem at bottom of front fork lower

5. See Figure

2-128. Measure distance between front

bracket.

brake line metal tubing and lower fork bracket adjacent to

pinch bolt. Move brake line assembly forward or back

a. XL

883R/XL 1200R: Remove screw with captive

until there is a 0.25 in. (6.35 mm) gap between brake line

washer (8) and clamp (9) to detach brake line mani-

and lower fork bracket

fold (11).

b. All other models: Remove screw with captive washer

1WARNING

(8) and clamp (7) to detach brake line (6).

Do NOT bend metal brake line to achieve the proper gap

CAUTION

between line and lower fork bracket. Bending the metal

brake line could cause metal fatigue and failure of the

Damaged banjo bolt surfaces will leak when reassembled.

front brake system, which could result in death or seri-

Prevent damage to seating surfaces by carefully removing

ous injury.

brake line components.

6. See Figure

2-127. While maintaining proper gap

4.

Remove banjo bolt (XL 883R/XL 1200R: 3, all others: 2)

between brake line and lower fork bracket, tighten screw

and washers (1) to detach brake line from master cylin-

(8) at bottom of front fork lower bracket to 120-168 in-lbs

der body. Discard washers.

(13.6-19.0 Nm).

5.

Remove banjo bolt and washers to detach brake line

7. Position new washers (1) on each side of banjo fitting at

from front brake caliper. Discard washers. XL 883R/XL

free end of brake line. Insert banjo bolt (2) through wash-

1200R: repeat this step for other front brake caliper.

ers and banjo fitting. Loosely install banjo bolt into cali-

6.

Carefully inspect brake line for dents, cuts or other

per. XL 883R/XL 1200R: repeat this step for other front

defects. Replace brake line if any damage is found.

brake caliper.

Installation

1.

See Figure 2-127. Note that hydraulic brake line is made

10529

up of thin tube construction and flexible hose sections.

Position new washers (1) on each side of banjo fitting on

end of brake line with shortest flexible hose section.

1

Insert banjo bolt (XL 883R/XL 1200R: 3, all others: 2)

through washers and banjo fitting. Loosely install banjo

bolt into master cylinder.

2.

From master cylinder, brake line runs downward in front

of right handlebar, where it turns inboard at front fork

upper bracket. Install clamp (4) around bottom fitting of

short flexible hose section. Loosely attach clamp to right

side of front fork upper bracket with screw (5).

3.

Continue running brake line downward crossing to left

side of the vehicle under front fork lower bracket.

4.

Clamp brake line to stem at bottom of front fork lower

2

bracket.

a. XL

883R/XL

1200R: Install screw with captive

washer (8) through brake line manifold (11) and

3

clamp (9). Loosely thread screw into front fork lower

bracket stem.

1.

Front brake line

b. All other models: Install clamp (7) around top fitting

2.

Lower fork bracket pinch bolt

of long flexible hose section. Loosely attach clamp

3.

Ruler

to front fork lower bracket stem with screw with cap-

tive washer (8).

Figure 2-128. Measuring Front Brake Line Clearance

2-78

2006 Sportster: Chassis

HOME

NOTE

x0574x2x

When installing clamp (4), bushing (12) and screw (5) in the

9

10

next step, make sure to adjust brake hose length between

rear caliper and clamp so there is no extra length. Do not

3

twist or stretch brake hose. Make sure bushing sits squarely

1

in clamp and around hose.

2

5. Install clamp

(4) with bushing (12) and screw (5), to

11

secure rear brake line to rear fork. Tighten screw to

30-40 in-lbs (3.4-4.5 Nm).

NOTE

6

Master cylinder and brake caliper housings have a positive

5

stop for banjo fitting. When tightening banjo bolt into master

4

cylinder and brake caliper in the next step, rotate banjo fitting

clockwise until it contacts positive stop.

7

6. Position new washers (1) on each side of banjo fittings

by rear brake master cylinder and rear brake caliper.

12

8

Insert banjo bolts (2) through washers and banjo fittings.

1.

Washers (4)

Tighten to 20-25 ft-lbs (27.1-33.9 Nm).

2.

Banjo bolt (2)

3.

Rear brake line

1WARNING

4.

Clamp

2

5.

Screw

After servicing brakes and before moving motorcycle,

1

6.

Brake line/switch tee

pump brakes to build brake system pressure. Insufficient

7.

Stop lamp switch assembly

pressure can adversely affect brake performance, which

8.

B-clamp

could result in death or serious injury. (00279a)

9.

Clamp

NOTE

10.

Screw

Rear brake master cylinder reservoir must be in a level posi-

11.

Screw

tion when filling and checking fluid level.

12.

Bushing

7. Position motorcycle upright (not resting on jiffy stand).

Figure 2-129. Rear Brake Line

Fill rear brake master cylinder reservoir with HARLEY-

DAVIDSON D.O.T. 5 BRAKE FLUID and bleed brake

Installation

system. See 1.9 BLEEDING HYDRAULIC BRAKE SYS-

TEM.

1.

See Figure 2-129. Thread stop lamp switch (7) into brake

line/switch tee (6) on new rear brake line (3). Hold hex

8. Tighten bleeder valve to

35-61 in-lbs

(4.0-6.9 Nm).

body of brake line/switch tee with an open-end wrench.

Install bleeder nipple cap.

Using a 1.0-in. (25.4 mm) six-point deep socket, tighten

9. Turn the ignition/light switch ON. Test operation of brake

stop lamp switch assembly to 80-123 in-lbs (9.0-13.9

lamp with the rear brake applied.

Nm).

2.

Feed rear brake line down through B-clamp (8).

1WARNING

3.

Position brake line/switch tee mounting bracket on bat-

After repairing the brake system, test brakes at low

tery tray bracket. Secure with screw (11). Tighten to 72-

speed. If brakes are not operating properly, testing at

120 in-lbs (8.14-13.6 Nm).

high speeds can cause loss of control, which could

4.

Install clamp (9) and screw (10) to secure rear brake line

result in death or serious injury. (00289a)

to battery tray bracket. Tighten screw to 30-40 in-lbs

10. Test ride motorcycle. If rear brake feels spongy, bleed

(3.4-4.5 Nm).

system again. See 1.9 BLEEDING HYDRAULIC BRAKE

SYSTEM.

2-80

2006 Sportster: Chassis

HOME

FRONT FORK

2.17

4. Withdraw slider tube from slider until lower bushing (10)

GENERAL

on slider tube contacts upper bushing (1) in slider. Use

lower bushing on slider tube in a slide hammer motion to

gently tap out oil seal (14), spacer (2) and upper bushing

from slider bore.

PART NO.

SPECIALTY TOOL

5. Remove sleeve (15). Sleeve will be found within slider or

HD-36583

Fork seal and bushing installation tool

on bottom end of damper tube (3).

The front fork consists of two telescoping tube/slider assem-

6. Insert a small diameter rod through opening in bottom of

blies. Each tube/slider assembly has an internal compression

slider tube to remove damper tube assembly.

spring, which supports the forward weight of the vehicle/rider

7. Remove rebound spring (8) from damper tube. Remove

and extends and retracts to cushion the ride over rough or

damper tube ring(s)

(4) from damper tube. Remove

irregular road surfaces. An oil-filled damping mechanism con-

lower bushing from damper tube only if replacement is

trols the telescoping action of each tube/slider assembly.

necessary.

REMOVAL

CLEANING, INSPECTION AND

1.

Remove front brake caliper. See REMOVAL under 2.14

REPAIR

FRONT BRAKE CALIPER. Remove front wheel assem-

bly. See FRONT WHEEL under 2.4 WHEELS.

1. Thoroughly clean and inspect all parts. Replace any

2.

Remove front fender mounting screws and locknuts.

parts that are bent, broken or damaged.

Remove fender. See 2.28 FRONT FENDER.

2. See Figure 2-131. Inspect the O-ring (6) for damage,

3.

See Figure 2-130. Loosen front fork upper and lower

wear or general deterioration; replace as necessary.

bracket pinch screws (11 and 14). Remove fork assem-

Replace all other removed seals.

blies from fork brackets.

3. Inspect damper tube ring(s) (4). Replace ring(s) if dam-

aged or excessively worn.

DISASSEMBLY

4. Check dust seal (12) where it contacts slider tube (9).

Dust seal should provide continuous contact against

1.

See Figure 2-131. Remove drain screw/washer (19) from

slider tube and should not show excessive wear. Check

slider (16). Remove tube cap (7) from slider tube (9).

slider tube where it is contacted by seal. Tube surface

Drain fork oil. Remove O-ring (6) from tube cap (7).

should be shiny, smooth and free of scoring or abrasions.

Remove spring (5) from slider tube.

5. Inspect small hole in groove of slider tube lower end. Ver-

2.

Remove cover (11) and dust seal (12). Compress inter-

ify that hole is unobstructed.

nal circle clip (13). Remove clip from groove in top of

slider bore.

3.

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.

2006 Sportster: Chassis

2-81

HOME

x0421d2x

7

0.42-0.50 in.

(10.7-12.7 mm)

13

6

10

9

6

8

11

13

x0423x2x

5

3

4

12

15

13

4

3

2

14

1

1. Front fork lower bracket and stem

2. Seal, lower

3. Bearing cone (2)

4. Bearing cup (2)

5. Seal, upper

6. Front upper bracket

7. Fork stem clamp screw

8. Washer

9. Fork stem bolt

10. Fork stem bolt cap (XL 1200R only)

11. Pinch screw, upper (2)

12. Tube cap

13. Fork (front slider and tube assembly, RH and LH)

14. Pinch screw, lower (2)

15. Steering head (part of frame)

Figure 2-130. Front Fork Assembly

2-82

2006 Sportster: Chassis

HOME

x0420x2x

ASSEMBLY

7

8

1.

See Figure 2-131. Install new lower bushing (10) in

groove of slider tube (9), if removed. Expand bushing

6

only enough to fit over tube.

2.

Install damper tube ring(s) (4) into groove(s) of damper

9

tube (3). Place rebound spring (8) over damper tube.

Insert damper tube into slider tube.

3.

Insert spring (5) into slider tube with the tapered end

5

down. Push damper tube through opening at bottom of

slider tube using spring. Place sleeve (15) over end of

damper tube.

4.

Install slider tube assembly into slider (16). 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, apply-

15

ing downward force on spring, final tighten screw.

5.

Place upper bushing (1), spacer (2) (concave side down-

ward), oil seal (14) (lettering side upward) and FORK

SEAL AND BUSHING INSTALLATION TOOL over slider

tube. Install bushing, spacer and seal into slider bore by

16

tapping components downward with the installation tool.

10

Install internal circle clip (13) into groove in top of slider

4

bore.

6.

Install dust seal (12) and cover (11) at top of slider. Install

11

drain screw/washer (19) into lower end of slider.

3

7.

Pour the proper amount of TYPE “E” HYDRAULIC FORK

12

OIL into top end of slider tube. See 1.20 FRONT FORK

OIL.

13

8.

Install slider tube cap (7) with O-ring (6). Tighten to 22-58

17

ft-lbs (29.9-78.7 Nm).

14

INSTALLATION

18

1.

See Figure 2-130. Insert fork slider (13) through front

fork lower

(1) and upper (6) brackets. Position slider

19

tubes so that top of each tube cap (12) extends 0.42-

2

0.50 in. (10.7-12.7 mm) above top surface of front fork

1

upper bracket.

2.

Tighten front fork upper and lower bracket pinch screws

1.

Upper bushing

(11 and 14) to 30-35 ft-lbs (40.7-47.5 Nm).

2.

Spacer

3.

Damper tube

3.

Install front fender. See 2.28 FRONT FENDER. Tighten

4.

Ring

fasteners to 96-156 in-lbs (10.9-17.6 Nm).

5.

Spring

4.

Install front wheel assembly and front brake caliper. See

6.

O-ring

FRONT WHEEL under 2.4 WHEELS.

7.

Tube cap

8.

Rebound spring

9.

Slider tube

10.

Lower bushing

11.

Cover

12.

Dust seal

13.

Internal circle clip

14.

Oil seal

15.

Sleeve

16.

Slider

17.

Washer

18.

Screw

19.

Drain screw/washer

Figure 2-131. Front Slider Tube/Slider Assembly

2006 Sportster: Chassis

2-83

HOME

REAR FORK

2.19

GENERAL

x0425d2x

PART NO.

SPECIALTY TOOL

5

HD-46281

Bearing remover/installer tool

4

REMOVAL

3

NOTE

Mark all hardware as it is removed so that it may be returned

to its original location.

1.

Support motorcycle under frame with suitable lifting

device so that rear wheel is off the ground.

1

6

2.

Remove rear wheel. See REAR WHEEL under 2.4

WHEELS.

3.

Remove rear brake caliper assembly from rear fork. See

REMOVAL under

2.15 REAR BRAKE CALIPER.

2

Remove screw securing brake line clamp to rear fork.

1.

Bolt (2)

4.

Remove both shock absorber screws, washers and nuts

2.

Bearing (2)

from rear fork. See REMOVAL under

2.20 REAR

3.

Rear fork

SHOCK ABSORBERS.

4.

Pivot shaft

5.

Remove rear belt guard and debris deflector. See 2.30

5.

Frame

BELT GUARD AND DEBRIS DEFLECTOR.

6.

Retaining ring

6.

Remove rear exhaust pipe. See 2.27 EXHAUST SYS-

Figure 2-132. Rear Fork Assembly

TEM.

7.

Remove rear brake reservoir cover. Remove reservoir

mounting screw and pull reservoir back out of the way.

See 2.13 REAR BRAKE MASTER CYLINDER RESER-

VOIR.

8.

Loosen, but do not remove, top mounting screw from left

passenger footrest bracket. Remove bottom mounting

screw. Move brake hoses and B-clamp forward slightly to

gain access to left rear fork/engine mount bolt.

9.

See Figure 2-132. Support rear fork (3). Remove rear

fork/engine mount bolts (1) and pull fork assembly from

frame.

2006 Sportster: Chassis

2-85

HOME

DISASSEMBLY

10619

3

NOTE

4

See Figure 2-132. Remove pivot bearings (2) only if replace-

ment is required.

1.

See Figure

2-133. Using BEARING REMOVER/

INSTALLER TOOL (4, 5, 6), carefully press bearing

assemblies from fork bearing bosses (2):

5

1

2

a. Place receiver cup (6) on press bed, with recessed

end of cup facing up.

b. Place rear fork pivot bearing boss (2) over cup as

shown in the photo.

c. Slide pilot (5) through bearing and into receiver cup.

6

d. Insert handle (4) through other rear fork pivot bear-

1. Rear fork

ing boss and bearing, down into pilot.

2. Pivot bearing boss

e. Engage press ram on end of handle and press bear-

3. Press

ing out.

4. Handle

2.

Turn rear fork over and press out other pivot bearing in

5. Pilot

the same manner.

6. Receiver cup

Figure 2-133. Removing Rear Fork Pivot Bearings

CLEANING AND INSPECTION

ASSEMBLY

1WARNING

1. See Figure 2-132. If necessary, press new bearings (2)

Compressed air can pierce the skin and flying debris

into position in rear fork, using BEARING REMOVER/

from compressed air could cause serious eye injury.

INSTALLER TOOL:

Wear safety glasses when working with compressed air.

a. See Figure 2-134. Place receiver cup (7) on press

Never use your hand to check for air leaks or to deter-

bed, with recessed end of cup facing up.

mine air flow rates. (00061a)

b. Place rear fork pivot bearing boss (2) over cup as

1.

Clean all components in solvent and blow dry with low

shown in the photo.

pressure compressed air. Carefully inspect bearings for

c. Place new pivot bearing (6) over pivot bearing boss,

wear and/or corrosion. Replace bearing assembly if

with retaining ring side of bearing up.

damaged.

d. Slide pilot (5) through new pivot bearing, through

2.

See Figure 2-132. Make sure pivot bearing retaining ring

pivot bearing boss, and into receiver cup.

(6) is not bent or damaged. If it is, replace it with a new

e. Insert handle (4) down into pilot.

retaining ring. Make sure retaining ring is fully seated in

the groove in each bearing (2).

f.

Engage press ram on end of handle and press bear-

ing down until retaining ring bottoms out in rear fork

3.

Check that rear fork (3) is not bent, twisted or cracked.

pivot bearing boss.

Replace if damaged.

2. Turn rear fork over and in the same manner, press in

other pivot bearing into rear fork pivot bearing boss.

2-86

2006 Sportster: Chassis

HOME

INSTALLATION

10620

1.

Slide rear fork assembly into position on motorcycle.

3

4

2.

See Figure 2-132. Holding rear fork assembly in position,

install rear fork/engine mount bolts (1). Tighten to 60-70

5

ft-lbs (81.4-95.0 Nm).

3.

Position rear brake hose B-clamp and left passenger

6

footrest bracket in place and install lower mounting

screw. Tighten both mounting screws to

45-50 ft-lbs

(61.1-67.9 Nm).

4.

Install rear exhaust pipe. Do not tighten fasteners at this

1

2

time.

7

5.

Install belt guard and debris deflector. See 2.30 BELT

GUARD AND DEBRIS DEFLECTOR.

6.

Install shock absorbers onto rear fork. See INSTALLA-

TION under 2.20 REAR SHOCK ABSORBERS.

10621

7.

Install rear brake caliper assembly. See INSTALLATION

4

under 2.15 REAR BRAKE CALIPER.

5

8.

Install rear wheel and adjust rear belt. See REAR

WHEEL under 2.4 WHEELS.

6

9.

Tighten all fasteners securing rear exhaust pipe and muf-

fler to vehicle. See INSTALLATION under

2.27

EXHAUST SYSTEM.

7

1.

Rear fork

2.

Pivot bearing boss

3.

Press

4.

Handle

5.

Pilot

6.

Bearing

7.

Receiver cup

Figure 2-134. Installing Rear Fork Pivot Bearings

2006 Sportster: Chassis

2-87

HOME

REAR SHOCK ABSORBERS

2.20

GENERAL

CLEANING AND INSPECTION

When removing shock absorbers, remove and install one

Clean and inspect all parts for wear and damage. Check rub-

shock absorber first, then the other. This will eliminate the

ber components for wear, cracking and stiffness. Examine

need to raise the rear end of the motorcycle. If it is necessary

shock assembly for signs of leakage. Replace both shock

to remove both shock absorbers at once, place the motorcy-

absorbers as a set if either rear shock absorber assembly is

cle on a suitable lift with the rear wheel raised off the ground.

excessively worn, leaking or damaged.

See 1.17 SHOCK ABSORBER ADJUSTMENT for informa-

tion on preload adjustment and suspension settings.

INSTALLATION

NOTE

1. See Figure 2-135. Install shock absorber upper mounting

Except for rubber mounting damper bushings, shock absorb-

screw (2), washer (3), stud cover (4) and shock absorber

ers are non-repairable items. If the shock absorber is leaking

(6).

or damaged, it must be replaced as an assembly.

2. Position bottom end of shock absorber against outboard

side of rear fork mount. Insert bolt (1) and washer (7)

REMOVAL

through damper bushing (8) and rear fork mount flange.

Install locknut (9) on end of bolt.

1.

If necessary, raise rear end of motorcycle with stand or

3. Remove upper mounting screw (2). Apply 2-3 drops of

suitable blocking underneath frame. If blocking is not

LOCTITE THREADLOCKER 243 (blue) to threads of

available, remove one shock absorber at a time. The

upper mounting screw.

remaining shock absorber will hold the rear fork and

4. Install washer

(3) onto upper mounting screw. Insert

frame in place.

screw through stud cover (4), upper shock absorber

2.

See Figure 2-135. Remove bolt (1), washer (7) and lock

damper bushing (5) and into frame boss. Tighten to 45-

nut (9) from bottom end of shock absorber (6).

50 ft-lbs (61.1-67.9 Nm).

3.

Remove screw (2), washer (3) and stud cover (4) from

5. Tighten lower shock absorber mounting screw to 45-50

top end of shock absorber.

ft-lbs (61.1-67.9 Nm).

4.

Remove shock absorber.

1. Bolt

x0426c2x

2. Screw

3. Washer

6

4. Stud cover

5. Damper bushing

6. Shock absorber

7. Washer

5

8. Damper bushing

4

9. Nut

3

10. Spring adjuster

9

11. Lower spring guide

12. Upper spring seat

13. Shock absorber cover

2

13

10

1

12

8

7

11

Figure 2-135. Rear Shock Absorber: All Models (Right Side Shown)

2-88

2006 Sportster: Chassis

HOME

STABILIZER LINKS

2.21

GENERAL

x0592a2x

4

2

3

4

The stabilizer link system allows the engine to “float” on its

rubber engine mounts while maintaining engine-to-frame

alignment. The stabilizer links provide a fixed alignment, and

no adjustment is necessary or possible.

UPPER FRONT STABILIZER LINK

8

Removal

1.

Position motorcycle upright on suitable lift.

2.

See Figure 2-136. Remove screws (4) and stabilizer link

(2).

5

3.

Remove stabilizer link bracket from frame.

7

6

1

a. All except XL 1200C: remove screws (5), washers

(8), horn bracket, and stabilizer link bracket (3) from

frame.

1.

Engine bracket

2.

Stabilizer link

b. XL 1200C: remove screws (5), washers (8) and sta-

3.

Stabilizer link bracket

bilizer link bracket (3) from frame.

4.

Screw (2)

4.

Remove screws (6), lock washers (7) and engine bracket

5.

Screw(2)

(1) from front cylinder head.

6.

Screw (2)

7.

Lock washer (2)

Installation

8.

Washer (2)

1.

See Figure 2-136. Install screws (6), lock washers (7)

Figure 2-136. Upper Front Stabilizer Link Assembly

and engine bracket (1) to front cylinder head. Tighten to

55-65 ft-lbs (74.6-88.2 Nm).

2.

Install stabilizer link bracket to frame.

a. All except XL 1200C: install stabilizer link bracket

(3), horn bracket, screws (5) and washers (8).

b. XL 1200C: install stabilizer link bracket (3), screws

(5) and washers (8).

c. Tighten screws to 25-35 ft-lbs (33.9-47.5 Nm).

3.

Install stabilizer link (2). Secure with screws (4). Tighten

to 25-35 ft-lbs (33.9-47.5 Nm).

2006 Sportster: Chassis

2-89

Content      ..     9      10      11      12     ..