Motorcycle Repair: Changing the lower legs, damper rod, phillips drain


Question
I have a 2000 FXST. I want to put chrome lower legs on it. Not sure how to go about it and would like to have instructions on how to go about it?

Answer
You should get a factory service manual part #99482-00A for $58 from your Harley dealer.  Anyway, use a hand impact driver to loosen the phillips drain screws at the bottom rear of the fork legs and drain the oil.  Take the top caps off with the front end jacked up or frame supported.  Remove front wheel, caliper, and fender.  Mark the axle spacers left and right because they are not the same length.  Remove the damper screw (up into the hole in the very bottom end of the fork tube) using a long 6mm allen bit and a hand impact driver to break it loose.  Notice it has a copper sealing washer.  Once the allen screw is out you can remove the lower leg by pulling up the dust boot, prying out the snap ring, and then using the lower leg as a slide hammer, slam the lower leg up and down to knock out the oil seal and washer and remove the lower leg.  The damper rod end will probably still be inside the lower leg.  It's a short aluminum cup that has to go on the end of the damper rod before you try to screw the new chrome lower up through the bottom.  We take the tubes out of the top tree just to use a slider tool to knock the oil seal back into the chrome lower before you slide the leg assembly back up through the the triple trees.  Always check the inside of the chrome lowers and clean them if necessary before installing them.  Put everything back in the reverse order.  Don't forget to put 12 ounces (356 cc) of type E fork oil in each leg.  Tighten the left axle nut first and then the right clamp.