Jim's Cartridge Fork Tool For 02 and up Baggers

The 2002 and newer baggers with fairings have a cartridge in the left side fork tube which requires a special tool to disassemble and reassemble for the proper servicing of the fork oil.
I believe in 06 on they went to the conventional left fork slider.

Here's the instructions for the lowering kit used on these bikes.
http://www.box.net/shared/24sia43s4w

Here's the tool for doing this, and it is available here.
JIMS.....Performance Parts for Harley-Davidson Motorcycles

TQuentin1 · 05-19-2008, 04:12 PM

OK, fine and dandy. That is the "right" way to do it. But I just want to change out the oil in the front fork. Right side is like it is supposed to be, and like my Dyna is on both sides. But the left, ...!! Now, what is the "quick and dirty" way to do this side?

TQ

glider · 05-19-2008, 04:16 PM

Remove the fork leg ,invert and drain/refill it. No easy way unless you update the left fork to the non cartridge one like on the non fairing bikes.(road kings)

Part # 46495-06 runs about $178 with a discount for the left leg.

Search For A Part on Zanotti

TQuentin1 · 05-20-2008, 12:45 AM

I can do the flip 'n flood if that gets the old oil out of the fork leg. Will try that.

On the replacement part, what is the impact of replacing the current setup? Why did HD go with this setup? It seems unnecessarily complicated if a "normal" setup will work just as well.

TQ

glider · 05-20-2008, 08:03 AM

Quote:

Originally Posted by TQuentin1

I can do the flip 'n flood if that gets the old oil out of the fork leg. Will try that.

On the replacement part, what is the impact of replacing the current setup? Why did HD go with this setup? It seems unnecessarily complicated if a "normal" setup will work just as well.

TQ

I often wonder that myself. I believe they were trying to improve handling but the 06 and newer baggers went back to the conventional forks on both sides without the cartridges in the left side.

TQuentin1 · 05-20-2008, 10:56 AM

OK. I think I will wait until the legs start to leak before replacing them with non-cartridge version.

The original owner of this bike had it lowered by the dealership - front and back. I had to replace the rear air shocks a while ago, but have not been into the fork. With the fork lowered (I am assuming the standard lowering kit from HD), what is the air gap supposed to be? I do not have any paperwork on the Harley kit which I suspect would specify a different measurement.

TQ

glider · 05-20-2008, 12:45 PM

Quote:

what is the air gap supposed to be?

Not sure what you are looking for here, are you referring to the PSI in the shocks? Different year bikes have different pressures, you would be safe with 5-10 lbs.

TQuentin1 · 05-20-2008, 01:10 PM

No, I am talking (writing) about the air gap above the fork oil in the legs. Manual calls for 5 1/2" on the standard setup. Since I don't have the paperwork that came with the lowering kit, I am not sure what the "new" spec is for the air gap on the lowered legs.

TQ

glider · 05-20-2008, 01:54 PM

I see what you are saying now. It's the measurement used in the cartridge side to refill. Best bet would be to contact the dealer, I believe the oil amount (measured) as opposed to inches is the same for a lowered fork as a regular one but I wouldn't want to give you bad info.

TQuentin1 · 05-21-2008, 12:09 AM

Found these instructions online:

http://mysite.wanadoo-members.co.uk/.../07/j02546.pdf

TQ

05-19-2008, 04:12 PM	#2 (permalink)
TQuentin1 Moderators Ride: '03 FLHTCUI Join Date: 2008, Apr 04 Location: Missouri City, TX Posts: 439	Re: Jim's Cartridge Fork Tool For 02 and up Baggers OK, fine and dandy. That is the "right" way to do it. But I just want to change out the oil in the front fork. Right side is like it is supposed to be, and like my Dyna is on both sides. But the left, ...!! Now, what is the "quick and dirty" way to do this side? TQ

05-19-2008, 04:16 PM	#3 (permalink)
glider Community Liaison Ride: 07 Road King Classic Join Date: 2007, Jun 21 Posts: 10,151 My Mood:	Re: Jim's Cartridge Fork Tool For 02 and up Baggers Remove the fork leg ,invert and drain/refill it. No easy way unless you update the left fork to the non cartridge one like on the non fairing bikes.(road kings) Part # 46495-06 runs about $178 with a discount for the left leg. Search For A Part on Zanotti Last edited by glider : 05-19-2008 at 04:27 PM.

05-20-2008, 12:45 AM	#4 (permalink)
TQuentin1 Moderators Ride: '03 FLHTCUI Join Date: 2008, Apr 04 Location: Missouri City, TX Posts: 439	Re: Jim's Cartridge Fork Tool For 02 and up Baggers I can do the flip 'n flood if that gets the old oil out of the fork leg. Will try that. On the replacement part, what is the impact of replacing the current setup? Why did HD go with this setup? It seems unnecessarily complicated if a "normal" setup will work just as well. TQ

05-20-2008, 10:56 AM	#6 (permalink)
TQuentin1 Moderators Ride: '03 FLHTCUI Join Date: 2008, Apr 04 Location: Missouri City, TX Posts: 439	Re: Jim's Cartridge Fork Tool For 02 and up Baggers OK. I think I will wait until the legs start to leak before replacing them with non-cartridge version. The original owner of this bike had it lowered by the dealership - front and back. I had to replace the rear air shocks a while ago, but have not been into the fork. With the fork lowered (I am assuming the standard lowering kit from HD), what is the air gap supposed to be? I do not have any paperwork on the Harley kit which I suspect would specify a different measurement. TQ

05-20-2008, 01:10 PM	#8 (permalink)
TQuentin1 Moderators Ride: '03 FLHTCUI Join Date: 2008, Apr 04 Location: Missouri City, TX Posts: 439	Re: Jim's Cartridge Fork Tool For 02 and up Baggers No, I am talking (writing) about the air gap above the fork oil in the legs. Manual calls for 5 1/2" on the standard setup. Since I don't have the paperwork that came with the lowering kit, I am not sure what the "new" spec is for the air gap on the lowered legs. TQ

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05-20-2008, 01:54 PM	#9 (permalink)
glider Community Liaison Ride: 07 Road King Classic Join Date: 2007, Jun 21 Posts: 10,151 My Mood:	Re: Jim's Cartridge Fork Tool For 02 and up Baggers I see what you are saying now. It's the measurement used in the cartridge side to refill. Best bet would be to contact the dealer, I believe the oil amount (measured) as opposed to inches is the same for a lowered fork as a regular one but I wouldn't want to give you bad info.

05-21-2008, 12:09 AM	#10 (permalink)
TQuentin1 Moderators Ride: '03 FLHTCUI Join Date: 2008, Apr 04 Location: Missouri City, TX Posts: 439	Re: Jim's Cartridge Fork Tool For 02 and up Baggers Found these instructions online: http://mysite.wanadoo-members.co.uk/.../07/j02546.pdf TQ

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Jim's Cartridge Fork Tool For 02 and up Baggers

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