®

INSTRUCTIONS

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REV. 11-19-96

Kit Number 46029-97

GENERAL

HERITAGE SPRINGER FRONT END KIT

This kit is designed for installation on 1996 and later Softail motorcycles. See Service Parts illustrations for kit contents.

NOTE

We recommend this kit be installed by a factory trained technician at an authorized Harley-Davidson Dealership.

NOTE

When installing this front end kit on FLSTC models, a turn signal kit, Part No. 68409-97, must also be installed.

1

WARNING

Do not install this front end kit on any non-approved motorcycle. Installation of the FLSTS Springer front end on anything other than Softail models could lead to possible personal injury. Do not install on three-wheeled vehicles of any kind.

This kit is designed for use with the supplied 16 in. front wheel. Do not use any other front wheel with this kit. Use of a different front wheel could adversely affect handling and result in personal injury.

Use only the fender that comes with the kit. Other fenders may not fit properly and can endanger the rider.

1

WARNING

The rider’s safety depends on the correct installation of this kit. USE THE APPROPRIATE SERVICE MANUAL

PROCEDURES. If the procedure is not within your capabilities or if you do not have the correct tools, have your Harley-Davidson Dealer perform the installation.

1

WARNING

The components of your FLSTS Springer front end and their design relationship to each other are very important. Altering these relationships by modifying the

FLSTS Springer front end could adversely affect the handling of the motorcycle and cause personal injury.

Use only Dunlop D402F tires with this kit. Using any other tire, or a tire with a higher aspect ratio, could allow the front wheel to bind on the fender during hard stops or big bumps.

DO NOT alter the fender to modify the fender location relative to the tire. Doing this could allow the front wheel to bind on the fender during hard stops or big bumps or adversely affect the handling characteristics of this motorcycle.

DO NOT change the front brake hardware. The FLSTS

Springer front brake hardware was designed to hold the brake components in position under any foreseeable circumstance.

DO NOT use front end components that have been remanufactured (straightened, plated, welded) in any way. There can be no certainty that remanufactured front end components will have the strength of the original, unchanged components.

Harley-Davidson has designed and manufactured this custom front end according to our very stringent and well-tested standards. If you modify the FLSTS Springer front end in any way that changes our original design,

Harley-Davidson cannot and does not assume responsibility for mishaps resulting from these changes.

1

WARNING

The FLSTS motorcycle was NOT designed for sidecar use. The FLSTS Springer fork was NOT designed for sidecar use. DO NOT use either the motorcycle or any

FLSTS Springer fork equipped vehicle for this purpose.

Use of any FLSTS Springer fork equipped vehicle for this purpose could cause personal injury.

DISASSEMBLY

NOTE

See applicable Service Manual for detailed disassembly procedures.

A Service Manual for your motorcycle is available from your

Harley-Davidson Dealer.

1

WARNING

To avoid accidental start-up of vehicle and possible personal injury, disconnect the battery cables before proceeding. Always disconnect the negative cable first. If the positive cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion resulting in personal injury.

1.

Remove seat and disconnect battery (negative cable first).

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1

WARNING

Gasoline is extremely flammable and highly explosive under certain conditions. Be sure engine is cold and do not smoke or allow open flame or sparks anywhere in the area when refueling or servicing fuel system. Doing so could result in fire or explosion causing personal injury.

2.

Drain gas and remove fuel tanks.

3.

Remove air cleaner and backplate and disconnect throttle cables from carburetor.

4.

Disconnect front end wiring systems at connectors located between fuel tanks. Feed wires through upper fork bracket.

5.

Remove hand controls, switch housings and turn signals from handlebar.

6.

Remove the following original parts: front wheel, inner tube, fork, upper and lower fork brackets, risers, handlebar, axle, headlight, throttle cables, steering head bearings, bearing races, front brake line and wheel spacers.

INSTALLATION

Bearing Races and Fork Assembly

1.

See Service Parts illustration on page 9. Install new bearing races (27) from kit using Kent-Moore tool Part

No. HD-39302.

2.

Pack new top and bottom bearings with Special

Purpose Grease, Part No. 99857-97, available at your

Harley-Davidson dealer. (Bottom bearing is installed on new fork assembly).

3.

Install fork assembly into frame steering head with new upper bearing (28) and new upper dust shield (29).

Secure fork assembly to frame with hex bearing retainer

(23).Tighten hex bearing retainer to 40-45 ft-lbs to seat bearings, then back off retainer. Retighten retainer to

10-12 ft-lbs for initial steering head adjustment.

4.

Fill steering head with Special Purpose grease by pumping grease into fitting, located on left side of steering head, until grease comes out by top and bottom dust cover. Wipe off excess grease.

NOTE

Be certain to maintain recommended steering head bearing lubrication intervals. FLSTS steering head bearings should be lubricated through the neck fitting with Special Purpose grease at every 2500 mile service interval; and remove, inspect, and repack bearings at every 20,000 mile service interval.

Risers and Handlebar

1.

See Service Parts illustration on page 9. Install upper triple clamp (22) and riser studs (32). Tighten studs to

60-65 ft-lbs.

NOTE

Install riser studs (32) in the following three steps: a.

Start threads of both studs in fork leg.

b.

Tighten both studs securely.

c.

Torque both studs to 60-65 ft-lbs.

2.

Apply anti-seize to upper triple clamp pinch bolt (21), install and tighten to 25-30 ft-lbs.

3.

Lubricate outside of riser bushings (33) and install one on each rigid fork leg stud. Install one into the top of each riser (34).

4.

Place risers in position over riser studs.

NOTE

Be certain the risers are installed correctly oriented to the handlebars.

5.

Install washers (35) and new locknuts (36). Tighten locknuts to 25-30 ft-lbs. Place ground spring (37) in one of the risers.

6.

Place handlebars on risers and put riser caps (38) in position. Install socket head screws (39). Adjust handlebars and tighten socket head screws to 12-15 ftlbs, making gap between caps and risers even, front and rear.

7.

Install new handgrip on left handlebar. To install handgrip, apply Fellobond 205 adhesive to inside surface of handgrip.

8.

Install original hand controls, master cylinder, and switch housings on handlebars. Install new throttle cables into right handlebar control and leave cable ends that attach to carburetor loose for now.

9.

Install turn signals on handlebars.

NOTE

Turn signals are not supplied in this kit. If this kit is being installed on a FLSTC model, purchase and install Handlebar

Mounted Turn SIgnal Kit, Part No. 68409-97).

10. Use new harness clips from kit to secure switch and directional wires to handlebars.

Link and Caliper Brackets

1.

See Service Part illustration on page 10. Assemble link

(42) to caliper bracket assembly (46) using screw (41), washer (60), and acorn nut (43). Tighten acorn nut to 35-

40 ft-lbs.

2.

Install rubber spacer (48) and thrust washer (47) onto pivot sleeve on left rocker. Gray surface of thrust washer should face inward.

3.

Assemble link and caliper bracket by sliding caliper bracket onto pivot sleeve on rocker, and assemble link to fork leg bracket (44) using screw (40), washer (60), and acorn nut (43). Tighten acorn nut to 35-40 ft-lbs.

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Brake Line

1

WARNING

Brake line routing is critical. Brake line must not contact springs or spring fork components. Contact with any of these components could cause wear in brake line. This could cause leakage and brake failure, possibly resulting in personal injury.

1.

See Service Parts illustration on page 12. Insert brakeline

(96) through front fork assembly. Brakeline must go in behind left fork leg above the lower fork casting and come out in front of the right fork leg.

1

WARNING

Caution must be used not to bend or twist the brakeline.

This could cause misalignment, leakage and brake failure, possibly resulting in personal injury.

3.

Loosely assemble brakeline to lower fork casting on left side with screw (97). See Figure 1.

4.

Assemble clamp (101) and throttle cable retainer wire clip to upper rigid fork casting using screw (92). See

Figure 2.

6034

NOTE

Be certain that the straight end of the wire clip is under and in contact with the fork stop tab on the upper fork casting.

5.

With brake line in place, tighten mounting screws.

Fender

1.

Fender should already be painted to match rest of motorcycle.

NOTE

Special care must be taken to avoid getting paint in bearing bores or on threads.

2.

See Service Parts illustration on page 13. Press spherical bearings (102) into fender. Race of bearings should be installed flush with the inboard side of fender bushings.

3.

Feed fender lamp assembly (113) wire harness into fender top hole and out through side hole.

4.

Place harness into metal clip inside of fender and carefully close clip to hold harness in place.

5.

Using alcohol, or glass cleaner, lubricate the rubber grommet of the lamp assembly and place it into position in the hole on top of the fender. Install small grommet

(116) in side of fender.

6.

Loosely install rear lamp housing screw (114).

7.

Install front lamp housing screw (115) while holding nut from inside of fender, and tighten screw securely.

8.

Tighten rear lamp housing screw securely.

9.

Gently pull the wire harness out the side of the fender until there is a minimum of slack under the fender. Be sure that there is as much wire harness to tire clearance as possible.

10. Insert wire terminals into 2 place connector housing.

11. Install from outside the nylon insert assemblies (104 and 105) into each fender bushing and push assemblies up against spherical bearing races.

Figure 1

6035

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Figure 2

Figure 3

s0125x2x

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s0125x2x

6.

Install thick spacer (107) onto axle with large O.D. of spacer to outside of bushing.

7.

Install castlenut (108). Tighten castlenut to 60 ft-lbs (81

Nm) and check to see if special clip (109) can be installed. If required, tighten nut just enough to align hole and nut slots.

8.

Insert special pin through axle hole.

1

WARNING

DO NOT operate motorcycle without special pin installed or handling may be adversely affected resulting in personal injury.

9.

Install left and right hub cap seals (110) and right and left hub caps (111). Tighten until hubcap makes contact, then tighten 1/4 turn more.

Figure 4

1

CAUTION

Installation of the front fender on FLSTS front end is different from other models due to tight clearances. Use a clean shop rag to protect fender paint from damage.

12. See Figures 3 and 4. Slide fender into position keeping right fork leg between fender and struts.

13. Raise fender until fender holes are aligned with fork holes for axle.

14. While holding fender in position, slide axle through the fender and front end to temporarily support assembly.

15. Install screw (117), washer (118), and nut (120).

Tighten nut to 18-22 ft-lbs (24-30 Nm). Install spring clip

(119) on screw.

Wheel

1.

Mount tire, balance wheel, and install original disc on new wheel. Refer to applicable Softail Service Manual for detailed procedure.

1

WARNING

Do not replace the specified Dunlop D402F tire with a higher aspect ratio tire. Doing this could adversely affect the handling of the motorcycle and cause personal injury.

2.

Remove front axle.

3.

See Service Parts illustration on page 10. Place right hand conical spacer (62) and left hand flat spacer (70) into wheel hub.

4.

See Service Parts illustration on page 13. Install thin spacer (106) onto axle with large O.D. end of spacer contacting axle head.

5.

Install front wheel assembly and slide axle through fender, rockers, and wheel from the right side of the motorcycle.

Brake Caliper

1

WARNING

Whenever a caliper is installed, BEFORE moving motorcycle, you must pump brake fluid pressure back up until the pistons push the pads against the brake disc. If you don’t pump fluid pressure up again, the brakes will not be available to stop the motorcycle, possibly resulting in personal injury.

1

WARNING

D.O.T. brake fluid can cause eye irritation. In case of contact with eyes, flush with plenty of water and get medical attention. KEEP BRAKE FLUID OUT OF THE

REACH OF CHILDREN!

1

WARNING

Whenever a hydraulic brake line or fitting is opened, the fitting should be flushed with brake fluid and the brake system must be bled. Do this to eliminate any air or contaminents from the brake system. Air in the fluid will cause the brake pedal to have a spongy feel. If a contaminant becomes lodged in the seat of a fitting or the sealing surface, leakage of fluid could occur and air could be drawn into the system, possibly causing brake failure and personal injury.

1

WARNING

Do not re-use brake pad mounting plate. Use of original brake pad mounting plate could cause front brake failure and possible result in personal injury. Use new brake caliper assembly from kit with brake pads. Refer to Softail Service Manual for detailed procedure.

1.

Place caliper mounting plate, with disc pad, on disc.

2.

See Figure 5. Install brake caliper (B) on brake disc.

The brake bracket has a cast-in nub that engages a hole in the mounting plate.

3.

Position the caliper with the disc between the friction pads. Slide the caliper mounting plate into brake caliper from the rear. Be sure that the spring clip on the caliper mounting plate is properly positioned on the brake caliper.

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s0129x2x

B

F

G

A Lower mounting bolt

B Brake caliper

C Washer

D Upper mounting bolt

A

E

E Cotter pin

F Banjo washers

G Banjo bolt

C

D

Figure 5

4.

Place flat washer (C) on upper mounting bolt (D), then insert the bolt through the bracket holes and the mounting plate. Screw the bolt into the threaded bushing.

5.

Coat the outside diameter of lower mounting bolt (A) with Dow Corning MOLY 44 grease. Insert the lower mounting bolt through the caliper and the bracket hole.

Thread the bolt into the tapped hole at the lower end of the mounting plate. Tighten lower mounting bolt to 25-

30 ft-lbs (34-41 Nm).

6.

Tighten upper mounting bolt (D) to 42-46 ft-lbs (57-62

Nm). Install cotter pin (E).

7.

Install brake line on caliper with banjo washers (F). Hold brake line in place and tighten banjo bolt (G) to 17-22 ftlbs (23-30 Nm). Install brake line clamp and brake line clamp bolt.

8.

Turn handlebars so master cylinder is level. Fill reservoir with D.O.T. 5 HYDRAULIC BRAKE FLUID to

1/8 in. (3.2 mm) below top.

9.

Install the master cylinder cover. Actuate the master cylinder and check for leaks. Bleed the brakes following instructions in your Service Manual.

Passing Lamps and Horn

1.

Disconnect VOES hose (A) from carburetor.

2.

Slide fuel line protection sleeve (B) off of fuel line.

3.

Loosen hex nut on back of enrichner knob and disconnect from VOES/horn bracket.

4.

Remove horn by removing acorn nut and flange nut at horn bracket. Disconnect horn wire and horn ground wire from horn and remove wires from retainer clip on back of horn.

5.

Trace horn ground wire back to termination and remove from motorcycle.

6.

Disconnect VOES connector.

7.

Remove VOES/horn bracket by removing 3 screws and sliding bracket off of fuel hose.

8.

Remove VOES with hoses from bracket. Remove fuel line grommet and install grommet in new VOES bracket

(C).

9.

Apply spot light label (D) to new VOES bracket. The hole in the label should be concentric with the hole in the bracket.

10. Assemble VOES assembly (E) to new bracket using new clip.

11. Insert screw used to mount bracket to motorcycle into outer most hole on VOES bracket. This may not be possible once the switch is assembled.

13. Assemble passing lamp switch (F) to VOES bracket.

Position switch so wires are in rearward position.

Tighten nuts on both sides of VOES bracket to lock switch into place.

i00815

E

C

F

B

A

D

Headlamp

1.

See Service Parts Diagram, page 12. Fasten headlamp mounting block (82) behind upper shock mount, applying Loctite 242 (blue) to socket head screw (85).

Attach headlamp to mounting block.

A VOES hose

B Fuel line sleeve

C VOES bracket

D Spot light label

E VOES assembly

F Passing lamp switch

Figure 6

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14. Reinsert fuel hose back through grommet in bracket, and slide bracket back in place.

15. Insert remaining two screws through VOES bracket and reassemble bracket to motorcycle with original nuts.

Torque nuts to 30 ft-lbs (41 Nm).

16. Reconnect VOES connector.

17. Locate Yellow/Black horn wire. Notice it is looped over and restrained with black tear tape. Grab horn wire close to tape and pull firmly outward to release the extra horn wire.

18. Route horn wire forward under upper triple clamp, between upper rebound springs, to horn.

19. Reinstall enrichner knob into VOES bracket and tighten hex nut.

20. Slide fuel line protective sleeve back over the fuel line.

21. Reconnect VOES switch hose to carburetor.

22. See Service Parts illustration on page 12. Assemble horn to passing lamp assembly as follows: a.

Assemble horn ground wire to right hand terminal on horn.

b.

Assemble horn to lamp assembly using screws (90) and nuts (91), trapping horn ground wire between back of horn bracket and left horn mounting nut.

23. See Service Parts illustration on page 9. Place shock

(2) into position on motorcycle with with top fastener left loose.

24. Place passing lamp bracket onto motorcycle and tighten top shock absorber fastener.

25. Finish wire connections as follows: a.

Route passing lamp wires back between upper rebound springs and under upper triple clamp to passing lamp harness connector [73] and mate connector halves.

b.

Route headlamp harness back between upper rebound springs and under upper triple clamp and mate headlamp harness connector [38].

c.

connect Yellow wire spade terminal to Yellow passing lamp switch harness wire [connector 74].

d.

Mate fendertip wire connector [32].

After making wire connections, cable strap any loose wires and check that no wires are pulled or pinched when front end travels from full left to full right position.

1

WARNING

Always connect the positive battery cable first. If the positive cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion producing personal injury.

26. Install fuel tanks, connect battery, positive cable first, and install seat.

1

WARNING

After installing seat, pull upward on front of seat to be sure it is locked in position. If seat is loose, it could shift position during vehicle operation and startle the rider, causing loss of control and personal injury.

27. Check all electrical circuits, including brake lights, headlamp and turn signals, for proper operation. Follow procedure in Softail Service Manual to aim headlamp.

Springer Steering Head Bearing

Adjustment

NOTE

The fork has more weight on the left side than the right side.

The balance point is just right of center.

1.

Raise motorcycle so that wheels are off the floor an equal amount.

2.

See Service Parts illustration on page 9. Remove the acorn nut (19) and washer (20). Loosen, but do not remove, the upper triple clamp pinch bolt (21).

3.

Place a suitable marking material, such as masking tape, over the front fender tip.

4.

Find the balance point of the front end.

5.

Install a pointer so the base is stationary on the floor and the pointer is centered on the fender.

6.

Tap the fender on one side until the front end begins to fall away by itself. Mark this point on the marking material. Repeat on the other side.

NOTE

The correct distance between the fall away marks must be 1-

2 inches (25-50 mm).

7.

Tighten or loosen the hex bearing retaining nut (23) as necessary until the fall away distance is 1-2 inches.

8.

Tighten the triple clamp pinch bolt (21) to 25-30 ft-lbs

(34-41 Nm).

9.

Install the rubber washer (20) and acorn nut (21).

Tighten acorn nut to 30-35 in-lbs (3.4-4.0 Nm).

10. Repeat measurement to verify adjustment is correct.

11. Install and adjust new throttle cables, and original clutch cable following applicable Service Manual procedures.

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i00816

RIGHT

PASSING

LAMP

FENDERTIP LAMP

[32B] [32A]

GY/BK

O/W

BK

[73A] [73B]

1

2

1

2

HEADLAMP

LEFT

PASSING

LAMP

GY/BK

Y

[74A]

1

1

Y

[74B]

O/W

W

Y

BK

[38B]

1

2

3

4

REAR VIEW

PASSING LAMP

SWITCH

[24A]

3

4

1

2

5

6

O/W

Y

BE

W

W/V

Y/BK

LEFT

TURN

SIGNAL

HORN

Y/BK

RIGHT

TURN

SIGNAL

BK

Figure 7

BK

BN

BE

BE

V

BK

[31B]

4

5

6

1

2

3

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Service Parts, pages 9 and 10, Illustration legend

PART NO.

ITEM DESCRIPTION

22

23

24

25

26

27

28

18

19

20

21

14

15

16

17

29

30

31

7

8

9

10

11

12

13

5

6

3

4

Spring and Rigid Fork Components

1 Screw

2 Shock absorber assembly

Washers (4)

Acorn nuts (4)

Spring fork

Acorn nuts (2)

Springs, inner compression (4)

Spring rod assemblies (2)

Spring seats (4)

Springs, outer compression (2)

Spring cups, compression (2)

Travel bumpers (4)

Spring rod bushings (2)

Spring cups, rebound (2)

Springs, rebound (2)

Spring restraints (2)

Spring bridge assembly

Washers, spring rod (2)

Acorn nut

Washer, rubber

Pinch bolt

Upper triple clamp

Bearing retainer

Screw, spring bracket

Washer, spring bracket

Screws (3)

Bearing races (2)

Bearing cone

Dust shield

Rigid fork assembly

Screw

35

36

37

38

39

Handlebar Riser Components

32 Riser studs (2)

33

34

Riser rubbers (4)

Risers (2)

Washers (2)

Nuts (2)

Ground spring

Riser caps (2)

Screws (4)

6353

7959

6829

4350A

45491-97

48306-88

3538

7232

3533

48315-60

48345-60

48361-80

45633-97

4029A

855B

54484-97

6812

7680W

45619-97

45567-88

46054-88

45628-92

45937-88

46055-88

46056-88

45936-88

45935-88

46057-88

46053-88

46060-88

46065-88

56550-97

53157-97

56548-97

6756

7768W

46058-97

56538-88

3494A

ITEM DESCRIPTION

Suspension Lower End Components

40 Screw

41 Screw

57

58

59

60

53

54

55

56

46

47

48

49

50

51

52

42

43

44

45

Brake link

Acorn nuts (2)

Fork leg bracket

Screws (2)

Caliper bracket assembly

Thrust washer

Quad ring

Rocker, left hand

Rocker, right hand

Bearings (2)

Pivot studs, spring fork (2)

Pivot studs, rigid fork (2)

Washers (4)

Nuts (4)

Bearing, ball (4)

Bearing, race (2)

Bearing retainer assemblies (2)

Jam nuts (2)

Washers (2)

PART NO.

Front Laced Wheel Assembly (not shown) 43016-97

Hub Components (between rockers)

61 Axle

62 Right hand spacer

63

64

65

Oil seals (2)

Bearing cones (2)

Bearing races (2)

66

67

68

Hub

Sleeve

Shim pack

69

70

71

Spacer washer

Left hand spacer

Torx screws (5)

41116-97

43624-97

47519-83A

9137

9136

43673-97

43608-82

43290-82

43291-82

43292-82

43293-82

43294-82

43650-82

43360-97

3655

4164

4165

41047-97

7862

45656-97

4163

44235-97

6042

11260

45787-97

45629-97

9139

45683-90

45684-90

45662-88

7880

9141

9140

45655-88

45659-88

6812

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29

4

28

sp46029-1

4

®

Service Parts

19

20

Part No. 46029-97 Date 11/96

Springer Front End Kit

21

18

17

39

22

38

16

23

15

13

14

12

25

26

31

8

7

9

37

36

35

33

34

33

3

32

24

30

7

3

12

11

Lower bearing shown installed

3

1

2

3

27

6

4

10

5

Assembled on fork stem

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46029-2

®

Service Parts

Part No. 46029-97 Date 11/96

Springer Front End Kit

67

44

43

40

42

41

46

68

69

65

64

63

70 with item 46

45

60

53

57

58

57

60

54

43

56

55

54

51

49/50

47

48 with item 49

52

59

71

62

63

64

65

66

Stock (reuse)

61

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Service Parts, pages 12 and 13, Illustration legend

ITEM DESCRIPTION PART NO.

Handlebar (not shown)

Handlebar grip (not shown)

Handlebar clips (4) (not shown)

Throttle cable assembly (not shown)

129 Throttle cable ferrules

55933-97

56206-94A

56073-83

56338-96

56508-76

85

86

87

88

81

82

83

84

Headlamp/Passing Lamps/Horn Components

72 Headlamp Assembly 67906-97

73 Passing Lamps (2) 68758-97

74 Cable straps (2)

(for securing fendertip lamp wiring to front brake line)

Wire connector sockets (2)

10065

73191-96 75

76

77

78

79

80

Connector housing

Passing lamp bracket

Clamp blocks (2)

Nuts (2)

Grommets (2)

73152-96WE

58089-97

68720-62

7892

11410

89

90

91

Screws (2)

Mounting block

Screws (2)

Washers (2)

Screw

Horn

Horn ground wire (not shown)

Horn cover

Screws (3)

Screws (2)

Locknuts (2)

3538

67892-93

2917

6379W

3214

69070-97

70410-97

69069-97

2939

2447

7624

95

96

97

98

99

Brake Components

92 Screw

93

94

Throttle cable retainer (not shown)

Banjo bolt (master cylinder)

Seal washers (2) (master cylinder)

Brake line

Screw

Banjo bolt (caliper)

Seal washers (2)(caliper)

100

101

127

Flange screw (not shown)

Clamp

Washer (not shown)

3538

10190

41739-84A

41733-88

45091-97

4091

41747-82A

41731-88A

44215-97

10076

6019

Caliper Assembly (not shown, see Figure 5) 44079-97

ITEM DESCRIPTION

For Fuel Tank Installation

125 Fuel line clamp

PART NO.

114

115

116

117

118

119

120

128

Fender Components

102 Spherical bearings (2)

103

104

Fender

O-rings (2)

105

106

107

108

Nylon inserts (2)

Spacer, right side

Spacer, left side

Nut

109

110

111

112

113

Clip

Hub cap seals (2)

Hub caps (2)

Mounting pad

Fender lamp assembly

(bulb is P.N. 52441-95)

Screw

Screw

Grommet

Screw/with hole for spring clip

Washer

Spring pins (2)

Locknut

Nut, keps

9194

59164-97

11261

9207

9196

9268

7987

508

43467-97

43466-97

59355-97

59357-97

2447

2448

11437

3268

6109

509

7739

7838

VOES/Passing Lamp Bracket Assembly Components

121 Passing lamp switch 67915-97

122

123

124

Spotlight label

Bracket

Retaining nut

(item 121-124 not shown, see Figure 6)

68798-97

69127-97

11192

10014

126 Cable Straps (4)

(for securing wiring to frame) 10006

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sp46029-3

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Service Parts

Part No. 46029-97 Date 11/96

Springer Front End Kit

94

72

95

73

76

75

74

85

83

84

82

84

83

81

80

90

78

79

77

91

86

88

89

96

99

98

92

101

97

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Service Parts

Part No. 46029-97 Date 11/96

Springer Front End Kit

114

113 115

103

116

117

112

108

109

119

120

118

111

106

110

105

104

102

s0126a2x

106

Axle

102

104

105

107

107

Spacer Orientation

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i00842

109

47

106

107

19

108

125

25

35

117

41

40

48

26

81 x 2

98

G

76

99

F

24

94

84

116

95

39

20

118

90

128

36

91

120

31

4

43

83

21

3 x 4

60 x 2

85

127

C

100

D

119

E

119

89

97

115

114

124

1

71

(numbers correspond to index numbers on Service Parts pages, letters correspond to Figure 5)

Common Hardware Specifications and Notes (parts and special hardware not listed)

1 Screw, 3/8-16 x 2 socket head

3 Washer, 13/32 x 11/16 x 1/16

4 Acorn nut, 3/8-16

21 Screw, 3/8-16 x 1-1/2 socket head

24 Screw, 5/16-24 x 1/2 button head

25 Lockwasher, 5/16 external tooth

26 Screw, 5/16-24 x 3/8 button head

31 Screw, 3/8-16 x 2-1/4 socket head

35 Washer, 1/2 x 1-1/16 x 3/32

36 Locknut, 1/2-13 x 19/32 x 3/4 hex

39 Screw, 5/16-18 x 7/8 socket head

43 Acorn nut, 3/8-16, locking (dimple on side)

60 Washer, 13/32 x 11/16 x 1/16

71 Screw, 5/16-18 x 7/8 Torx pan head

81 Screw, 5/16-24 x 1/2 button head

83 Screw, 3/8-16 x 3/4 socket head

84 Washer, 3/8 x 5/8 x 3/64

85 Screw, 3/8-16 x 1-1/4 socket head (thread cutting)

91 Locknut, # 10-24 x 1/4 x 3/8 hex

97 Screw, # 10-24 x 1/2 washer head (self-tapping)

108 Castle nut, 5/8-18 x 15/16 hex

118 Washer, 5/16 x 11/16 x 1/8

120 Locknut, 5/16-18 x 11/32 x 1/2 hex

128 Hex nut, # 10-24 (keps)

Identification Photo for Loose

Hardware and Small Parts

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