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REV. 2011-06-22
DYNA TRIPLE CLAMP KITS
4.
GENERAL
Kit Number
46311-07, 46313-07, 46317-07
Refer to STEERING HEAD in the Service Manual, and
follow the instructions to:
a.
Remove the fork sides.
b.
Remove the headlamp from the lower fork bracket
(triple clamp).
c.
Remove the bearing adjuster nut (D), and pull the fork
stem (E) and lower fork bracket (F) out of the steering
head. Set the adjuster nut aside for later re-assembly.
d.
Remove and retain the upper dust shield (4), and the
bearing cone and roller assembly (3) from the fork
stem. Remove the fork stem and bracket from the
vehicle frame.
e.
Check the condition of the bearing cups (races, Items
I and J) inside the steering head tube, and replace if
necessary. Bearing cones and cups should always
be replaced as sets if their condition is questionable.
Refer to STEERING HEAD: CLEANING AND
INSPECTION in the Service Manual.
Models
These kits fit 2006 and 2007 Dyna model motorcycles.
Tools and Supplies Required
Special Purpose Grease (H-D Part Number 99857-97) is
required for this installation and is available from a HarleyDavidson Dealer.
A Steering Head Bearing Race Installer (Part Number H-D39302) MAY also be needed, along with a small quantity of
engine oil.
The rider's safety depends upon the correct installation
of this kit. Use the appropriate service manual procedures.
If the procedure is not within your capabilities or you do
not have the correct tools, have a Harley-Davidson dealer
perform the installation. Improper installation of this kit
could result in death or serious injury. (00333a)
5.
Pack the new lower bearing cone with grease, and install
the dust shield and bearing cone onto the fork stem (E).
If the bearing cup has been replaced or is dry, lubricate
with engine oil as indicated in STEERING HEAD:
ASSEMBLY in the Service Manual.
NOTE
This instruction sheet references Service Manual information.
A 2007 Dyna Service Manual is required for this installation
and is available from a Harley-Davidson Dealer.
6.
Kit Contents
Insert the fork stem and bracket assembly into the frame
steering head.
Obtain the upper bearing cone (H), dust shield (G), and
bearing adjuster nut (D) removed earlier.
See Figure 1 and Table 1.
INSTALLATION
Pack the upper bearing with grease, and lubricate the
bearing cup with engine oil as necessary. See STEERING
HEAD: ASSEMBLY in the Service Manual.
NOTE
Cover the fuel tank with clean shop towels to prevent
scratching. Damage to the finish could result.
1.
Obtain the new lower fork bracket assembly (1), lower
bearing cone (3) and dust shield (4) from the kit.
See Figure 1. Remove and retain the fork stem cap (A).
Bend the lockwasher (B) tab away from the fork stem nut
(C). Remove and retain the fork stem nut.
7.
Install the upper bearing cone onto the fork stem, followed
by the dust shield.
8.
Thread the adjuster nut onto the fork stem, and tighten to
23-27 ft-lbs (31.0-36.6 Nm)
Back the bearing adjuster nut off about 180 degrees (onehalf turn).
Remove and discard the lockwasher.
2.
Remove the handlebar assembly with the risers and
bushings, and set them back onto the protected fuel tank.
Refer to HANDLEBAR: REMOVAL in the Service Manual.
3.
Loosen the upper fork bracket (triple clamp) pinch bolts
(6) and remove the upper fork bracket (2) along with the
handlebars. Be sure not to kink or pinch the control cables.
NOTE
Over-tightening the bearing adjuster nut will cause excessive
bearing wear, leading to the need for premature replacement.
9.
Tighten the adjuster nut until there is no noticeable shake
or free play between the bearings and cups. The fork
stem MUST turn freely from side to side.
10. Install the new upper fork bracket (2) and the hardened
washer (5) from the kit.
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Install the handlebar assembly with the risers and bushings. Refer to HANDLEBAR: INSTALLATION in the Service Manual.
14. Adjust the steering head bearings. See STEERING HEAD
BEARINGS: ADJUSTMENT (FALL-AWAY) in the Service
Manual, with the following exceptions:
11. Use a few drops of engine oil to lubricate the threads of
the fork stem nut (C) removed earlier. Thread the nut onto
the fork stem, and tighten securely.
a.
Tighten the fork stem nut to 70-80 ft-lbs (95-108 Nm)
before checking fall-away, and again after the check
has been completed.
12. Install the headlamp assembly. See HEADLAMP in the
Service Manual.
b.
The lock washer with lock tab is no longer installed
so bending the tab is not required.
13. Obtain the four socket head cap screws (6) from the kit,
to be used as the pinch bolts in the upper and lower fork
brackets. Refer to FRONT FORK in the Service Manual,
and follow the instructions to install the fork sides.
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15. Install the fork stem cap (A) removed earlier.
16. Align the headlamp. Refer to HEADLAMP ALIGNMENT
in the Service Manual.
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SERVICE PARTS
is04637
I
A
C
3
5
B
4
2
1
6
E
F
D
G
6
H
K
J
Figure 1. Service Parts, Dyna Triple Clamp Kits
Table 1. Service Parts Table
Kit
Item
Description (Quantity)
Part Number
Kit 46311-07
FXD, FXDB, FXDC models
1
Lower fork bracket (triple clamp) assembly
45867-08
2
Upper fork bracket (triple clamp) assembly
45538-08
Kit 46313-07
FXDL models
1
Lower fork bracket (triple clamp) assembly
45539-08
2
Upper fork bracket (triple clamp) assembly
46278-08
Kit 46317-07
FXDWG models
1
Lower fork bracket (triple clamp) assembly
46386-08
2
Upper fork bracket (triple clamp) assembly (polished)
46700-08
Items common
to ALL Kits
3
Lower bearing cone and roller assembly
48300-60
4
Lower dust shield
48198-06
5
Flat washer (hardened)
45727-08
6
Socket head cap screw, 3/8-16 x 1.5 inch, Grade 8 (4)
4352
Items mentioned in text, but not included in kit:
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A
Fork stem cap
B
Lockwasher
C
Fork stem nut
D
Bearing adjuster nut
E
Fork stem
F
Lower fork bracket
G
Upper dust shield
H
Upper bearing cone and roller assembly
I
Lower bearing cup
J
Upper bearing cup
K
Retaining ring
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