Author Topic: Rebuilding front forks (to get rid of cartridge)  (Read 5712 times)

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Offline shovel66

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Rebuilding front forks (to get rid of cartridge)
« on: Wednesday, December 02, 2009. 01:39:36 PM. »
Hello,
Let me first say that I have searched and read about all the threads concerning changing the 2002-2005 cartridge style left fork to conventional spring style.  There was a wealth of knowledge and saved me trial and error and hours of research.  Thanks to all.

My two reasons for doing this is to put black lower sliders and black "cowbells" to blacken out the front end.  The other is for ease of changing fork oil in the future.  If I end up putting the Race Tech Gold Valve Cartridge Fork Emulators in, is the fork oil change still as easy?   :crook:

Thanks,
Chad
1966 FLH, 1972 FLH
2004 FLHTI

Offline TexasBowhunter

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Re: Rebuilding front forks (to get rid of cartridge)
« Reply #1 on: Wednesday, December 02, 2009. 03:39:39 PM. »
just as easy as the conventional forks are...Piece of cake...
paul
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Offline Deye76

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Re: Rebuilding front forks (to get rid of cartridge)
« Reply #2 on: Wednesday, December 02, 2009. 04:39:36 PM. »
Or install the guts from current front ends (2006 up IIRC). Sliders are the same, oil easy to change.
East Tenn.

Offline shovel66

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Re: Rebuilding front forks (to get rid of cartridge)
« Reply #3 on: Thursday, December 03, 2009. 05:34:39 AM. »
Looks like it would be easier and less of a hastle to buy complete 2006 fork assemblies and then just put my black lower sliders on.  I priced out to rebuild my forks to 2006 internals and it's not much less than buying complete assemblies.  Does anyone know if they are completely assemblied with lower sliders and filled with oil?  Part numbers 46495-06 (LH) and 46502 (RH)
Thanks,
Chad
1966 FLH, 1972 FLH
2004 FLHTI

Offline hogasm

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Re: Rebuilding front forks (to get rid of cartridge)
« Reply #4 on: Thursday, December 03, 2009. 05:45:25 AM. »
Buy the Progressive Suspension ones for $99 from Eastern Performance and you wont be disappointed
04 SEEG
02 FLHTC

Offline harleyjt

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Re: Rebuilding front forks (to get rid of cartridge)
« Reply #5 on: Thursday, December 03, 2009. 08:11:06 AM. »
Looks like it would be easier and less of a hastle to buy complete 2006 fork assemblies and then just put my black lower sliders on.  I priced out to rebuild my forks to 2006 internals and it's not much less than buying complete assemblies.  Does anyone know if they are completely assemblied with lower sliders and filled with oil?  Part numbers 46495-06 (LH) and 46502 (RH)
Thanks,
Chad
 

I looked at doing this a while back when I had the 05, and my understanding was the fork assemblies are complete, full of oil and ready to install.
jt
2014 Ultra Classic - Mysterious Red/Blackened Cayenne

Offline Jeffd

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Re: Rebuilding front forks (to get rid of cartridge)
« Reply #6 on: Thursday, December 03, 2009. 09:19:07 AM. »
Looks like it would be easier and less of a hastle to buy complete 2006 fork assemblies and then just put my black lower sliders on.  I priced out to rebuild my forks to 2006 internals and it's not much less than buying complete assemblies.  Does anyone know if they are completely assemblied with lower sliders and filled with oil?  Part numbers 46495-06 (LH) and 46502 (RH)
Thanks,
Chad

yes they come assembled, filled with oil and ready to bolt on right out of the box. 

Offline TexasBowhunter

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Re: Rebuilding front forks (to get rid of cartridge)
« Reply #7 on: Thursday, December 03, 2009. 09:47:17 AM. »
Just to add a bit more...
the 09 FLH's front ends have all new -09 part numbers
So you may want to convert over to the newer front end...It will all interchange with your model...
paul
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Paul

Online Ken R

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Re: Rebuilding front forks (to get rid of cartridge)
« Reply #8 on: Thursday, December 03, 2009. 12:13:44 PM. »
The left and right front forks, complete and ready to install retail for 260.00.  (20% less if you buy discount).

I think I paid about $116 for the parts to change to standard non-cartridge shock.  It's not a difficult task.  I have the list of parts needed somewhere.  Several have used my list with success.  

Ken

« Last Edit: Thursday, December 03, 2009. 12:17:21 PM. by Ken R »

Online Ken R

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Re: Rebuilding front forks (to get rid of cartridge)
« Reply #9 on: Thursday, December 03, 2009. 12:16:36 PM. »
Here, I found the list I made up and used several years ago.  It's on several forums now.

From Ken R:
Below you can find the COMPLETE list of parts you will need. I believe that I spent about $116.00 for the parts from Zanotti's. Can't remember if that was with shipping, or if that was a bit extra.

===============================


P/N: 45803-97 STOP, oil lock
P/N: 45838-77 BOLT, front fork
P/N: 45845-77 O-RING
P/N: 45859-77A RING, piston damper tube
P/N: 45890-97 TUBE ASSEMBLY
P/N: 45891-97 DAMPER tube assembly
P/N: 45892-02 SPRING, fork
P/N: 45933-86 SPRING, rebound

The sliders for 99 - 06 are all the same whether cartridge or non-cartridge.

In addition, you'll need two new seals, P/N 45875-84A and two containers of fork oil.


You'll have one part, (P/N 45838-77) that you could have used from the old parts instead of buying new, but I have it listed here so that when finished, your converted fork will match the parts catalogs. After I finished, I discovered that I didn't really have to purchase this $22.50 part, the old one is different but it would have worked just fine.

The conversion is really very easy. It only took me 3 hours, start to finish. I could do it in a couple of hours now.
To set the new seal, I used some 1-1/2" PVC pipe, slit so that it would slide over the fork tube and push the seal into place.

« Last Edit: Friday, December 04, 2009. 07:14:38 AM. by Ken R »

Offline shovel66

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Re: Rebuilding front forks (to get rid of cartridge)
« Reply #10 on: Thursday, December 03, 2009. 12:21:02 PM. »
Ah, Ken.  I already found your old post, printed it out and looked up the parts at Zanottis.  Great information and economical to change.  You are right, Ken, but I didn't want to have a new rebuilt one on the one side and a worn one on the other.  Even then I would still have pre-2006 style forks without the damping valve on the newer models.  There are just too many choices now.  It all comes down to how far I want to take it and how much money I'm willing to spend. 
Chad
1966 FLH, 1972 FLH
2004 FLHTI

Offline Deye76

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Re: Rebuilding front forks (to get rid of cartridge)
« Reply #11 on: Thursday, December 03, 2009. 03:53:24 PM. »
shovel, one thing to consider is, if you like the ride of your current cartridge parts, then don't use the heavier SE fork oil with new upgrades. The ride will be considerably more harsh.
East Tenn.

Offline TexasBowhunter

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Re: Rebuilding front forks (to get rid of cartridge)
« Reply #12 on: Friday, December 04, 2009. 07:51:08 PM. »
Chad,
here's some more to absorb...
Not too much difference, here are the parts from bottom to top:

2007 Road Glide
45933-86 REBOUND SPRING FC/FF/FS/FV/KB
46422-06 DAMPER TUBE FC/FF/FS/FV/KB
45859-77A RING, damper tube FC/FF/FS/FV/KB
46209-06 DAMPING VALVE FC/FF/FS/FV/KB
46235-06 SPRING FC/FF/FS/FV/KB
---------------------------------------------------------
2009 Road Glide
45933-86 REBOUND SPRING FC/FF/FS/FV/KB
46422-09 DAMPER TUBE, w/ 45859-77A FC/FF/FS/FV/KB
45859-77A PISTON RING, damper tube FC/FF/FS/FV/KB
46209-09 DAMPING VALVE FC/FF/FS/FV/KB
46235-09 SPRING FC/FF/FS/FV/KB

best of luck
paul
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Paul

Offline shovel66

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Re: Rebuilding front forks (to get rid of cartridge)
« Reply #13 on: Sunday, December 06, 2009. 02:22:20 PM. »
I would like to thank everyone for all the assistance and experience you've shared.  I ended up ordering the complete right and left fork assemblies for a 2009 FLHT.  I will be putting the black lower sliders and cowbells (I had locally powdercoated) and then installing them on the bike.  Unfortunately I won't have the time to do this until after Christmas.  Good things come to those who wait. 
Chad
1966 FLH, 1972 FLH
2004 FLHTI

Offline rideonfasterlouder

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Re: Rebuilding front forks (to get rid of cartridge)
« Reply #14 on: Tuesday, December 08, 2009. 08:24:40 AM. »
I know that the Street Glide and the Road King Custom are very similar so does any one know if the 09 forks for a 09 Street
Glide will fit a 04 Road King Custom?  This sure sounds like a simple solution to the cartridge.

Offline rideonfasterlouder

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Re: Rebuilding front forks (to get rid of cartridge)
« Reply #15 on: Tuesday, December 08, 2009. 08:41:03 AM. »
Also shovel what are the part numbers for the forks please if you dont mind.  Think I will do same to my Road Glide.

Offline TexasBowhunter

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Re: Rebuilding front forks (to get rid of cartridge)
« Reply #16 on: Tuesday, December 08, 2009. 10:08:44 AM. »
Yes the forks will interchange with one another
However the sliders won't due to the Brimbo calipers,,,this has changed the bolt locations from what I understand...
However if all you want to do is change the guts then yes the tubes and everthing else inside is bolt-up and play...
paul
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Paul

Offline waskier01

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Re: Rebuilding front forks (to get rid of cartridge)
« Reply #17 on: Tuesday, December 08, 2009. 12:23:03 PM. »
The brembos will fit on the 2000 forks. The rotors are larger. The stock harley -06 cartridge emulator has a weaker spring than the -09 cartridge emulator. 

Offline aal

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Re: Rebuilding front forks (to get rid of cartridge)
« Reply #18 on: Tuesday, December 08, 2009. 05:56:45 PM. »
Are the newer style forks noticeably better, as far as ride and handling?

Offline reh3

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Re: Rebuilding front forks (to get rid of cartridge)
« Reply #19 on: Tuesday, December 08, 2009. 06:30:07 PM. »
Quote
However the sliders won't due to the Brimbo calipers,,,this has changed the bolt locations from what I understand...


The sliders are the same for both types of calipers. When I changed over to a single sided brake on my street glide, I also switched to a brembo for the single setup. Waskier is right about the rotor size, the brembo rotors are 11.8 and the others are 11.5. Several dealers told me the legs were different, but when I ask why harley list the same chrome legs for 00 and later touring models, regardless of caliper type, none of them had an answer.

« Last Edit: Tuesday, December 08, 2009. 11:56:26 PM. by Fatboy_SirGarfield »

Offline TexasBowhunter

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Re: Rebuilding front forks (to get rid of cartridge)
« Reply #20 on: Wednesday, December 09, 2009. 09:19:21 AM. »
Quote
However the sliders won't due to the Brimbo calipers,,,this has changed the bolt locations from what I understand...


The sliders are the same for both types of calipers. When I changed over to a single sided brake on my street glide, I also switched to a brembo for the single setup. Waskier is right about the rotor size, the brembo rotors are 11.8 and the others are 11.5. Several dealers told me the legs were different, but when I ask why harley list the same chrome legs for 00 and later touring models, regardless of caliper type, none of them had an answer.



Thanks for the clarification on this...
paul
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Paul

Offline shovel66

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Re: Rebuilding front forks (to get rid of cartridge)
« Reply #21 on: Thursday, December 10, 2009. 02:55:01 AM. »
I ordered part #46495-09 and 46502-09 from the local dealership.  Yes, I could have gotten them $32 cheaper from Zanotti's but wouldn't have any local support if something was wrong or if I needed help with something.  When I looked in the 2009 parts catalog for FLHT front forks, it listed the lower sliders with xxxx-00A part numbers.  I suspect the "A" being that the one side has bolts that thread into the slider holding the axle clamp on instead of the studs with nuts holding it on. 

Since I don't have the service manual for a 2009 or 2010, can anyone tell me if the servicing or fork oil level is different than the procedures I have for the 2004 model? 

Thanks.
1966 FLH, 1972 FLH
2004 FLHTI

Offline TexasBowhunter

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Re: Rebuilding front forks (to get rid of cartridge)
« Reply #22 on: Thursday, December 10, 2009. 09:44:30 AM. »
It seems that on my 06 it was like 10.9 fluid oz....I just rounded it off to 11.0 oz since it was so close anyway...
Don't be anal as to getting the exact oz. because you can change buy adding or removing some to get a different feel...
When I changed the fluid in my 09 it seems it was 10.7 oz but I can't be for sure at this moment...
hope this helps
paul
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Paul

Offline shovel66

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Re: Rebuilding front forks (to get rid of cartridge)
« Reply #23 on: Thursday, December 10, 2009. 02:45:14 PM. »
Yes that certainly helps, Paul.  I usually add a tac more than the correct amount and then suck out the extra to level them off.  I can't wait to perform this upgrade.
Chad
1966 FLH, 1972 FLH
2004 FLHTI

Offline rideonfasterlouder

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Re: Rebuilding front forks (to get rid of cartridge)
« Reply #24 on: Friday, December 11, 2009. 05:57:15 AM. »
Thanks for part numbers shovel.  Keep us posted on how this works out.  I will probably copy cat your set up.  Did some more checking on the Road King and found out it already has conventional on both sides.