How to install samsumg WA5471 damper rods - Washing Machines

Nissan Frontier, Xterra 1998-05

• MAIN BEARING TORQUE SEQUENCE

Torque Specifications

Fig.
TORQUE SPECIFICATIONS
all readings in ft. lbs. Year Engine Displacement Liters (cc) Engine ID/VIN Cylinder Head Bolts Main Bearing Bolts Rod Brearing Bolts Crankshaft Damper Bolts Flywheel Bolts Manifold Spark Plugs Lug Nuts Intake Exhaust 1998 2.4 (2389) KA24DE
1A Step 1: 22 ft. lbs.
2B 10-12 ft. lbs. plus 60-65 degrees or 28-33 ft. lbs.
3
4C The cylinder heads and the lower intake manifold are installed together
TORQUE SPECIFICATIONS
all readings in ft. lbs. Year Engine Displacement Liters (cc) Engine ID/VIN Cylinder Head Bolts Main Bearing Bolts Rod Brearing Bolts Crankshaft Damper Bolts Flywheel Bolts Manifold Spark Plugs Lug Nuts Intake Exhaust 1999 2.4 (2389) KA24DE 3.3 (3277) VG33E
1A Step 1: 22 ft. lbs.
2B 10-12 ft. lbs. plus 60-65 degrees or 28-33 ft. lbs.
3
4C The cylinder heads and the lower intake manifold are installed together
TORQUE SPECIFICATIONS
all readings in ft. lbs. Year Engine Displacement Liters (cc) Engine ID/VIN Cylinder Head Bolts Main Bearing Bolts Rod Brearing Bolts Crankshaft Damper Bolts Flywheel Bolts Manifold Spark Plugs Lug Nuts Intake Exhaust 2000 2.4 (2389) KA24DE 3.3 (3277) VG33E
1A Step 1: 22 ft. lbs.
2B 10-12 ft. lbs. plus 60-65 degrees or 28-33 ft. lbs.
3
4C The cylinder heads and the lower intake manifold are installed together
TORQUE SPECIFICATIONS
all readings in ft. lbs. Year Engine Displacement Liters (cc) Engine ID/VIN Cylinder Head Bolts Main Bearing Bolts Rod Brearing Bolts Crankshaft Damper Bolts Flywheel Bolts Manifold Spark Plugs Lug Nuts Intake Exhaust 2000 3.3 (3277) VG33E
1A The cylinder heads and the lower intake manifold are installed together
2B 10-12 ft. lbs. plus 60-65 degrees or 28-33 ft. lbs.
3C Step 1: Tighten the cylinder head bolts to 22 ft. lbs.
4D Step 1: Tighten the connecting rod bearing bolts to 10-12 ft. lbs.
TORQUE SPECIFICATIONS
all readings in ft. lbs. Year Engine ID Engine Displacement Liters Cylinder Head Bolts Main Bearing Bolts Rod Bearing Bolts Crankshaft Damper Bolts Flywheel Bolts Manifold Spark Plugs Oil Pan Drain Plug Intake Exhaust 1998 KA24DE
1- Step 1: 22 ft. lbs.
2- 10-12 ft. lbs. plus 60-65 degrees or 28-33 ft. lbs.
3- The cylinder heads and the lower intake manifold are installed together
4- 10-12 ft. lbs. +60-65 degrees
5- Step 1: 72 ft. lbs.
6- Step 1: bolts 11-22 19 ft. lbs.
7- Step 1: 20 ft. lbs.
8- Step 1: 31 ft. lbs.
9- 83 inch lbs.
10- Stud bolt: 11 ft. lbs.
11- Step 1: 72 ft. lbs.
12- Bolts: 17-24 (M8) 16 ft. lbs.
13- Step 1: 33 ft. lbs.
14- Intake manifold collector:
15- Intake manifold:
TORQUE SPECIFICATIONS
all readings in ft. lbs. Year Engine ID Engine Displacement Liters Cylinder Head Bolts Main Bearing Bolts Rod Bearing Bolts Crankshaft Damper Bolts Flywheel Bolts Manifold Spark Plugs Oil Pan Drain Plug Intake Exhaust 1999 KA24DE VG33E
1- Step 1: 22 ft. lbs.
2- 10-12 ft. lbs. plus 60-65 degrees or 28-33 ft. lbs.
3- The cylinder heads and the lower intake manifold are installed together
4- 10-12 ft. lbs. +60-65 degrees
5- Step 1: 72 ft. lbs.
6- Step 1: bolts 11-22 19 ft. lbs.
7- Step 1: 20 ft. lbs.
8- Step 1: 31 ft. lbs.
9- 83 inch lbs.
10- Stud bolt: 11 ft. lbs.
11- Step 1: 72 ft. lbs.
12- Bolts: 17-24 (M8) 16 ft. lbs.
13- Step 1: 33 ft. lbs.
14- Intake manifold collector:
15- Intake manifold:
TORQUE SPECIFICATIONS
all readings in ft. lbs. Year Engine ID Engine Displacement Liters Cylinder Head Bolts Main Bearing Bolts Rod Bearing Bolts Crankshaft Damper Bolts Flywheel Bolts Manifold Spark Plugs Oil Pan Drain Plug Intake Exhaust 2000 KA24DE VG33E
1- Step 1: 22 ft. lbs.
2- 10-12 ft. lbs. plus 60-65 degrees or 28-33 ft. lbs.
3- The cylinder heads and the lower intake manifold are installed together
4- 10-12 ft. lbs. +60-65 degrees
5- Step 1: 72 ft. lbs.
6- Step 1: bolts 11-22 19 ft. lbs.
7- Step 1: 20 ft. lbs.
8- Step 1: 31 ft. lbs.
9- 83 inch lbs.
10- Stud bolt: 11 ft. lbs.
11- Step 1: 72 ft. lbs.
12- Bolts: 17-24 (M8) 16 ft. lbs.
13- Step 1: 33 ft. lbs.
14- Intake manifold collector:
15- Intake manifold:
TORQUE SPECIFICATIONS
all readings in ft. lbs. Year Engine ID Engine Displacement Liters Cylinder Head Bolts Main Bearing Bolts Rod Bearing Bolts Crankshaft Damper Bolts Flywheel Bolts Manifold Spark Plugs Oil Pan Drain Plug Intake Exhaust 2001 KA24DE VG33E
1- Step 1: 22 ft. lbs.
2- 10-12 ft. lbs. plus 60-65 degrees or 28-33 ft. lbs.
3- The cylinder heads and the lower intake manifold are installed together
4- 10-12 ft. lbs. +60-65 degrees
5- Step 1: 72 ft. lbs.
6- Step 1: bolts 11-22 19 ft. lbs.
7- Step 1: 20 ft. lbs.
8- Step 1: 31 ft. lbs.
9- 83 inch lbs.
10- Stud bolt: 11 ft. lbs.
11- Step 1: 72 ft. lbs.
12- Bolts: 17-24 (M8) 16 ft. lbs.
13- Step 1: 33 ft. lbs.
14- Intake manifold collector:
15- Intake manifold:
TORQUE SPECIFICATIONS
all readings in ft. lbs. Year Engine ID Engine Displacement Liters Cylinder Head Bolts Main Bearing Bolts Rod Bearing Bolts Crankshaft Damper Bolts Flywheel Bolts Manifold Spark Plugs Oil Pan Drain Plug Intake Exhaust 2002 KA24DE VG33E VG33ER
1- Step 1: 22 ft. lbs.
2- 10-12 ft. lbs. plus 60-65 degrees or 28-33 ft. lbs.
3- The cylinder heads and the lower intake manifold are installed together
4- 10-12 ft. lbs. +60-65 degrees
5- Step 1: 72 ft. lbs.
6- Step 1: bolts 11-22 19 ft. lbs.
7- Step 1: 20 ft. lbs.
8- Step 1: 31 ft. lbs.
9- 83 inch lbs.
10- Stud bolt: 11 ft. lbs.
11- Step 1: 72 ft. lbs.
12- Bolts: 17-24 (M8) 16 ft. lbs.
13- Step 1: 33 ft. lbs.
14- Intake manifold collector:
15- Intake manifold:
TORQUE SPECIFICATIONS
all readings in ft. lbs. Year Engine ID Engine Displacement Liters Cylinder Head Bolts Main Bearing Bolts Rod Bearing Bolts Crankshaft Damper Bolts Flywheel Bolts Manifold Spark Plugs Oil Pan Drain Plug Intake Exhaust 2003 KA24DE VG33E VG33ER
1- Step 1: 22 ft. lbs.
2- 10-12 ft. lbs. plus 60-65 degrees or 28-33 ft. lbs.
3- The cylinder heads and the lower intake manifold are installed together
4- 10-12 ft. lbs. +60-65 degrees
5- Step 1: 72 ft. lbs.
6- Step 1: bolts 11-22 19 ft. lbs.
7- Step 1: 20 ft. lbs.
8- Step 1: 31 ft. lbs.
9- 83 inch lbs.
10- Stud bolt: 11 ft. lbs.
11- Step 1: 72 ft. lbs.
12- Bolts: 17-24 (M8) 16 ft. lbs.
13- Step 1: 33 ft. lbs.
14- Intake manifold collector:
15- Intake manifold:
TORQUE SPECIFICATIONS
all readings in ft. lbs. Year Engine ID Engine Displacement Liters Cylinder Head Bolts Main Bearing Bolts Rod Bearing Bolts Crankshaft Damper Bolts Flywheel Bolts Manifold Spark Plugs Oil Pan Drain Plug Intake Exhaust 2004 KA24DE VG33E VG33ER
1- Step 1: 22 ft. lbs.
2- 10-12 ft. lbs. plus 60-65 degrees or 28-33 ft. lbs.
3- The cylinder heads and the lower intake manifold are installed together
4- 10-12 ft. lbs. +60-65 degrees
5- Step 1: 72 ft. lbs.
6- Step 1: bolts 11-22 19 ft. lbs.
7- Step 1: 20 ft. lbs.
8- Step 1: 31 ft. lbs.
9- 83 inch lbs.
10- Stud bolt: 11 ft. lbs.
11- Step 1: 72 ft. lbs.
12- Bolts: 17-24 (M8) 16 ft. lbs.
13- Step 1: 33 ft. lbs.
14- Intake manifold collector:
15- Intake manifold:
TORQUE SPECIFICATIONS
all readings in ft. lbs. Year Engine ID Engine Displacement Liters Cylinder Head Bolts Main Bearing Bolts Rod Bearing Bolts Crankshaft Damper Bolts Flywheel Bolts Manifold Spark Plugs Oil Pan Drain Plug Intake Exhaust 2005 QR25DE VQ40DE
1- Step 1: 22 ft. lbs.
2- 10-12 ft. lbs. plus 60-65 degrees or 28-33 ft. lbs.
3- The cylinder heads and the lower intake manifold are installed together
4- 10-12 ft. lbs. +60-65 degrees
5- Step 1: 72 ft. lbs.
6- Step 1: bolts 11-22 19 ft. lbs.
7- Step 1: 20 ft. lbs.
8- Step 1: 31 ft. lbs.
9- 83 inch lbs.
10- Stud bolt: 11 ft. lbs.
11- Step 1: 72 ft. lbs.
12- Bolts: 17-24 (M8) 16 ft. lbs.
13- Step 1: 33 ft. lbs.
14- Intake manifold collector:
15- Intake manifold:
Main Bearing Torque Sequence




Fig. Main bearing torque sequence-2.4L engine



Fig. Main bearing torque sequence-2.5L engine



Fig. Main bearing torque sequence-3.3L engine



Fig. Main bearing torque sequence-4.0L engine

You need to provide a model number in order to look over the parts list and see what type of auto damper your model has. There are ways to test an auto damper to see if it opens and close properly. An auto damper can be electrical or mechanical. Kenmore model numbers look like this example=> 321.2345789 and can be found artound the fresh food compartment door frame.

1 Turn power off to refrigerator.
2 Open the fresh food sections door and remove all items on top shelf.
3 Adjust the fresh food control to its coldest position.
4 Remove the light shield by pulling down on the back corners of the cover and then slide the cover forward.
5 Remove the edge sealing device, radiant shield supporting screws at the back bottom center of the control housing mounting screw at back, bottom center of the control housing. Slide the control housing to the right and lower the housing.
6 Disconnect the temperature control housing from electric quick disconnect.
7 Remove the temperature control housing from the refrigerator and then place on a
flat work surface.
8 Remove the auto damper control rod retainer, control rod and the slide control
gear from the auto damper control.
9 Now turn the control housing over.
10 Remove the two auto damper mounting screws, then remove the auto damper from the control housing.
11 Mark the auto damper rod about 1/4 in. from and away from the housing.
12 Uncoil the auto damper capillary tube at about 4 in.'s
13 Submerge into a glass of ice (not water). then watch for door to move to the closed
position.
14 Remove from ice and warm capillary tube with your hand. Then watch door for an opposite reaction.
15 If no movement is detected, replace the control. 61005971 Damper Control Assembly
The above is only a demostration of how to test a refrigerator with an auto that uses a capillary tube to open and close the damper. Your refrigerator will need to be identified by the correct model number to let you know what type of auto damper your model has, Post your model number and I will tell you what you will need to test yours, Thanks Sea Breeze

My Advantium 240 damper motor was cycling as mentioned above in the morning after a power failure had occurred. Removing the top vent grille and control panel I could see the inlet damper was opening fully and stopping about halfway closed then retrying. Removing power and cycling by hand, i could move it freely until just before it would contact the micro switch at home position where there was a hard stop. I removed the light assembly on top of the cavity and was able to access the rod that spans across to the outlet damper near the halogen light. A combination of fiddling with the connecting rod inside the light housing and manually cycling the inlet damper reseated the rod and everything was working again. My guess is the power failure was the cause and hopefully the issue won't return.

• After the rocker shaft assemblies are installed you need to make sure that the ball end of the push rods seat themselves.

• Now, rotate the engine clockwise until the torsional damper marks line up with the "0" on the timing tab.

• Now rotate the engine 3 1/2" measured at the damper. At this point the first mark on the damper is now aligned with the first lower water pump bolt.

• Now install the rocker shaft bolts and snug them to 40 foot lbs.

• If you have any comments please feel free to leave them here.
• Hope this helps and thank you for using FixYa.

Regards, Tony

I have no diagrams for you. MAke your own as you take it apart etc and take lots of cell phone pictures if you need help remembering how to put things back together.

Table 1-6. Type E Fork Oil Amounts

MODEL OZ CC IN. MM

FXDXT 11.5 341 6.10 154.9

FXDWG 12.0 356 7.28 184.9

FXDL 10.7 316 7.20 182.9

FXD 10.6 314 6.69 169.9

Changing fork oil is a simple mater for some models and requires fork disassembly for others. Here is the procedure for all 2001 DYNA models:

2001 DYNA FRONT FORK OIL 1.18

REPLACING FORK OIL Replace front fork oil at every 20,000 mile (32,000 km) service interval and/or prior to storage.

ALL BUT FXDX & FXDXT models

Raise and support the motorcycle so the front end is off the floor and the forks are fully extended, on FXDL models, remove the center plug from each fork cap, on all other models, remove the fork tube caps, remove the drain screws from the bottom of each fork and drain the fork oil, replace the drain screws and washers and tighten the screws

to 13-17 in-lbs (1.5-2.0 Nm) THEN see Table 1-6. and fill the fork with Harley-Davidson TYPE E FORK OIL (Part No. HD-99884-80) as set out in the Table. THEN if apart assemble the forks as follows:

a. FXD, FXDXT, FXDWG models: install both fork tube caps and tighten them to 11-22 ft-lbs (14.9-29.8 Nm).

b. FXDL models: install center plugs and tighten until secure.

Fork oil amounts can be measured two ways: use the oz./cc measurement if fork is left in frame; use the in./mm measurement if the fork is disassembled in which case the oil level is measured from the top of the fork tube with the spring removed and the fork fully compressed.

Table 1-6. Type E Fork Oil Amounts for 2001 DYNA

MODEL OZ CC IN. MM

FXDXT 11.5 341 6.10 154.9

FXDWG 12.0 356 7.28 182.9

FXD 10.6 314 6.69 169.9

PART NO. SPECIALTY TOOL

HD-41177 Fork tube holder

HD-41549A Fork spring compression tool

HD-41551 Spring plate tool

HD-36583 Fork seal installer

HD-59000A Pro-level oil gauge

FRONT FORKS: FXDX & FXDXT 2.20

REMOVAL

Raise and support the motorcycle so the front end is off the floor and the forks are fully extended, remove both front brake calipers and the front wheel, remove the front fender, remove the front fairing, remove the headlamp bracket and attach the headlamp to the frame using a rubber bungee strap, loosen the upper and lower triple clamp pinch bolts and pull the fork sides from the brackets.

DISASSEMBLY

Remove the stopper ring, remove the spring preload adjuster but DO NOT unthread the rebound adjuster from the damper rod because incorrect assembly could result in reduced adjustment range. THEN unthread the fork cap from the fork tube and allow the fork leg to drop, exposing the spring, THEN get a FORK SPRING COMPRESSION TOOL (Part No. HD-41549A) on the spring collar, turn the screws in to engage the holes in collar, compress the spring until the SPRING PLATE TOOL (Part No. HD-

41551) can be positioned between the spacer and the spring collar, THEN hold the fork bolt and compression adjuster, remove the fork bolt from the compression adjuster, remove the spring adjuster plate from the fork bolt, remove spacer, spring collar and spring, pour out the fork oil by pumping the fork leg and rod 8-10 times or until rod the moves freely. THEN position fork slider in vise using a FORK TUBE HOLDER such as (Part No. HD-41177) to avoid damage. THEN remove the socket head bolt, remove the damper from the fork tube, remove the cover from the slider, remove seal and stopper ring, pull the fork tube out of the slider, remove the oil seal, spacer and guide bushing from the fork tube.

CLEANING AND INSPECTION

Measure the fork spring free length and replace the spring if it is shorter than 17.00 in. (431.8 mm), check the fork tube and the slider for score marks, scratches or abnormal wear, check the slide and guide bushings for excessive wear or scratches, set the fork tube on V-blocks and measure runout which should not exceed 0.008 in. (0.2 mm).

ASSEMBLY

Coat the oil seal with TYPE E FORK OIL, before installing the slide bushing and guide bushing, lubricate them with fork oil, THEN install the guide bushing and the spacer seal noting that the guide bushing opening must be oriented to the side and NOT to the front or rear, THEN slip the slider into the fork tube, place the slide bushing over the fork tube until it rests on the slider, drive the guide bushing with the spacer seal into the slider, lubricate a new oil seal with TYPE E FORK Oil, drive the oil seal into the slider using FORK SEAL INSTALLER (Part No. HD-36583). install the stopper ring and dust seal, (if the rebound adjuster was removed from the damper rod bottom the lock nut on the threaded portion of damper rod, holding a thumb on the detent spring and ball, back out (turn counterclockwise) the rebound adjuster to the last "click." and then turn down (clockwise) 17 "clicks", thread the rebound adjuster onto the damper rod until the adjuster stops at maximum thread engagement (but do not force it), thread the locknut onto the damper rod up until it contacts the base of the rebound adjuster and tighten it in place), THEN holding the slider in a vise while being careful not to damage it. install the damper tube into the fork tube and tighten the socket screw and washer to 22-29 ft-lbs (29.8-39.3 Nm). THEN pour half the TYPE E FORK OIL into the fork tube, slowly pump the damper rod 10 or more times, position the damper rod in the fully bottomed position and pour the remaining amount of TYPE E FORK OIL into the fork tube. THEN using a PRO-LEVEL OIL GAUGE (Part No. HD-59000A) or similar adjust the oil level to 5.04 in. (128 mm). THEN carefully clean and install the spring, the spring collar, and the spacers with the sharp edge created when they were stamped out when manufactured, facing the collar. THEN using a FORK SPRING COMPRESSION TOOL such as (Part No. HD-41549A) push spring collar down and place a SPRING PLATE such as (Part No. HD-41551) between the spacer and the spring collar, install the fork cap and tighten it against the rebound adjuster to 22-29 ft-lbs (29.8-39.3 Nm). THEN tighten the fork cap onto the fork tube to 11-22 ft-lbs (14.9-29.8 Nm), install the spring adjuster plate, replace the O-rings on the spring preload adjuster and lubricate them with fork oil. THEN install the spring preload adjuster and the stopper ring and carefully drive the slider cover into the slider.

INSTALLATION

Insert both fork side assemblies up through the fork stem and bracket and upper bracket and tighten the fork stem bracket pinch bolt(s) to 30-35 ft-lbs (40.7-47.5 Nm). Then re-install the headlamp bracket, install the front fender, install the front wheel and the brake caliper When the motorcycle is again ready for the road adjust the headlamp and road test the motorcycle.

This is really annoying, happens with most Defenders, but is easily fixed. It is the steering damper. They are never strong enough. Best solution is to fit an additional damper onto the track rod. Remove the track rod protection bracket from under the rear of the front diff, fit a heavier track rod and mount an additional damper on the track rod. The other end of the damper is mounted on the rear of the diff (where the protection bracket was removed). Land Rover specialists such as MR Automotive in Brisbane will send you the required parts. You won't regret doing it!

Hopefully you will glean all you need to know from this but if you want or need more information or more FXD specific information PLEASE H

Hopefully the information below will be okay BUT if you need any more or any more specific information please post a comment and describe what you want/need.

REPLACING FORK OIL Replace front fork oil at every 20,000 mile (32,000 km) service interval and/or prior to storage.

ALL BUT FXDX & FXDXT models

Raise and support the motorcycle so the front end is off the floor and the forks are fully extended, on FXDL models, remove the center plug from each fork cap, on all other models, remove the fork tube caps, remove the drain screws from the bottom of each fork and drain the fork oil, replace the drain screws and washers and tighten the screws

to 13-17 in-lbs (1.5-2.0 Nm) THEN see Table 1-6. and fill the fork with Harley-Davidson TYPE E FORK OIL (Part No. HD-99884-80) as set out in the Table. THEN if apart assemble the forks as follows:

a. FXD, FXDXT, FXDWG models: install both fork tube caps and tighten them to 11-22 ft-lbs (14.9-29.8 Nm).

b. FXDL models: install center plugs and tighten until secure.

Fork oil amounts can be measured two ways: use the oz./cc measurement if fork is left in frame; use the in./mm measurement if the fork is disassembled in which case the oil level is measured from the top of the fork tube with the spring removed and the fork fully compressed.

Table 1-6. Type E Fork Oil Amounts for 2001 DYNA

MODEL OZ CC IN. MM

FXDXT 11.5 341 6.10 154.9

FXDWG 12.0 356 7.28 182.9

FXD 10.6 314 6.69 169.9

PART NO. SPECIALTY TOOL

HD-41177 Fork tube holder

HD-41549A Fork spring compression tool

HD-41551 Spring plate tool

HD-36583 Fork seal installer

HD-59000A Pro-level oil gauge

FRONT FORKS: FXDX & FXDXT 2.20

REMOVAL

Raise and support the motorcycle so the front end is off the floor and the forks are fully extended, remove both front brake calipers and the front wheel, remove the front fender, remove the front fairing, remove the headlamp bracket and attach the headlamp to the frame using a rubber bungee strap, loosen the upper and lower triple clamp pinch bolts and pull the fork sides from the brackets.

DISASSEMBLY

Remove the stopper ring, remove the spring preload adjuster but DO NOT unthread the rebound adjuster from the damper rod because incorrect assembly could result in reduced adjustment range. THEN unthread the fork cap from the fork tube and allow the fork leg to drop, exposing the spring, THEN get a FORK SPRING COMPRESSION TOOL (Part No. HD-41549A) on the spring collar, turn the screws in to engage the holes in collar, compress the spring until the SPRING PLATE TOOL (Part No. HD-

41551) can be positioned between the spacer and the spring collar, THEN hold the fork bolt and compression adjuster, remove the fork bolt from the compression adjuster, remove the spring adjuster plate from the fork bolt, remove spacer, spring collar and spring, pour out the fork oil by pumping the fork leg and rod 8-10 times or until rod the moves freely. THEN position fork slider in vise using a FORK TUBE HOLDER such as (Part No. HD-41177) to avoid damage. THEN remove the socket head bolt, remove the damper from the fork tube, remove the cover from the slider, remove seal and stopper ring, pull the fork tube out of the slider, remove the oil seal, spacer and guide bushing from the fork tube.

CLEANING AND INSPECTION

Measure the fork spring free length and replace the spring if it is shorter than 17.00 in. (431.8 mm), check the fork tube and the slider for score marks, scratches or abnormal wear, check the slide and guide bushings for excessive wear or scratches, set the fork tube on V-blocks and measure runout which should not exceed 0.008 in. (0.2 mm).

ASSEMBLY

Coat the oil seal with TYPE E FORK OIL, before installing the slide bushing and guide bushing, lubricate them with fork oil, THEN install the guide bushing and the spacer seal noting that the guide bushing opening must be oriented to the side and NOT to the front or rear, THEN slip the slider into the fork tube, place the slide bushing over the fork tube until it rests on the slider, drive the guide bushing with the spacer seal into the slider, lubricate a new oil seal with TYPE E FORK Oil, drive the oil seal into the slider using FORK SEAL INSTALLER (Part No. HD-36583). install the stopper ring and dust seal, (if the rebound adjuster was removed from the damper rod bottom the lock nut on the threaded portion of damper rod, holding a thumb on the detent spring and ball, back out (turn counterclockwise) the rebound adjuster to the last "click." and then turn down (clockwise) 17 "clicks", thread the rebound adjuster onto the damper rod until the adjuster stops at maximum thread engagement (but do not force it), thread the locknut onto the damper rod up until it contacts the base of the rebound adjuster and tighten it in place), THEN holding the slider in a vise while being careful not to damage it. install the damper tube into the fork tube and tighten the socket screw and washer to 22-29 ft-lbs (29.8-39.3 Nm). THEN pour half the TYPE E FORK OIL into the fork tube, slowly pump the damper rod 10 or more times, position the damper rod in the fully bottomed position and pour the remaining amount of TYPE E FORK OIL into the fork tube. THEN using a PRO-LEVEL OIL GAUGE (Part No. HD-59000A) or similar adjust the oil level to 5.04 in. (128 mm). THEN carefully clean and install the spring, the spring collar, and the spacers with the sharp edge created when they were stamped out when manufactured, facing the collar. THEN using a FORK SPRING COMPRESSION TOOL such as (Part No. HD-41549A) push spring collar down and place a SPRING PLATE such as (Part No. HD-41551) between the spacer and the spring collar, install the fork cap and tighten it against the rebound adjuster to 22-29 ft-lbs (29.8-39.3 Nm). THEN tighten the fork cap onto the fork tube to 11-22 ft-lbs (14.9-29.8 Nm), install the spring adjuster plate, replace the O-rings on the spring preload adjuster and lubricate them with fork oil. THEN install the spring preload adjuster and the stopper ring and carefully drive the slider cover into the slider.

INSTALLATION

Insert both fork side assemblies up through the fork stem and bracket and upper bracket and tighten the fork stem bracket pinch bolt(s) to 30-35 ft-lbs (40.7-47.5 Nm). Then re-install the headlamp bracket, install the front fender, install the front wheel and the brake caliper When the motorcycle is again ready for the road adjust the headlamp and road test the motorcycle.

The damper is usally installed with a damper installation set these are long all theaded studs with nuts and washers andyou screw in the right threaded stud and then install the damper then thewashers and then the nut tightening the nut to pull the damper on. It's very inportant to line up the key exatly as if oof just some it won't go on. I've all ways been able to clean everything with blaster line up the key carefully and tap it on with a light hammer just far enought to start the bolt then keep tapping as you tighten the bolt to help not stripping the thraeds as it's still staring as only t few threads are pulling after its halfway in you can turn it with an impac but tapping with the hammer may still help. heating the damper is riskly to do as the rubber insulation may get too hot and fail the rubber. You can dress the crank nose with a file but you need to do it carefully and evenly scraches made by sandpaper or poorly guilded file can make the shaft bigger as in sven tighter too get the damper on blaster and a rag rubbing both parts is safeest

1. Slightly loosen hub center nut when all four wheels are on ground.
2. Raise and support vehicle, then remove five wheel bolts and wheel.
3. Remove hub center nut, then the wheel sensor,
4. Press back brake piston using slip-joint pliers,
   
5. Remove caliper from steering swivel member, then suspend in wheel housing with cable tie.
6. Remove brake disc and back plate, then slightly loosen tie rod end nut.
7. Press out tie rod end nut using puller tool or equivalent.
8. Remove nut and tie rod end bolt, then the anti-roll bar to swinging arm nut.
9. Remove outer ball joint nut.
10. Press ball joint out of steering swivel member using puller tool or equivalent, installed on spring link.
11. Remove nut and discard. This self-locking nut must not be reused.
12. Remove three upper mounting nuts for MacPherson strut, then the strut.
13. Clamp MacPherson strut in vice.
14. Compress spring using spring compressor or equivalents.
15. Hold piston rod and remove nut using MacPherson strut socket tool 89 96 662, or equivalent. This is a self-locking nut and must not be reused.
16. Remove mounting and top spring seat, then the coil spring, gaiter and compression stop.
17. Unscrew damper using wrench tool No. 89 96 670, or equivalent, then remove damper from strut.
18. Reverse procedure to install, noting the following:

1. Screw damper in place using wrench tool No. 89 96 670, or equivalent.
2. Lower end of coil spring should abut against stop in bottom of spring cup.
3. Position MacPherson strut on vehicle and install three retaining nuts on top mounting. Tighten nuts alternately, according to specifications.
4. Always use new hub center nut with self-locking threads.