INSTRUCTIONS

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Kit Number 46196-00

REV. 10-28-99

FXSTSB (SPRINGER) FRONT END KIT

GENERAL
This kit is designed for installation on 1996 to 1999 FXSTSB model motorcycles. NOTE We recommend this kit be installed by a factory trained technician at an authorized Harley-Davidson Dealership. NOTE A Service Manual is necessary for performing the following detailed Assembly and Installation procedures. A Service Manual for your motorcycle is available from your HarleyDavidson Dealer. NOTE See Service Parts Illustrations for component Part Numbers and Locations.

1WARNING
This kit is designed for use with a 21 in. front wheel. Do not use any other front wheel with this kit. Use of a different front wheel could adversely affect handling which could result in death or serious injury.

1WARNING
Use only Dunlop D402F tires with this kit. Using any other tire, or a tire with a higher aspect ratio, could allow the front wheel to bind on the fender during hard stops or big bumps, which may lead to an accident which could result in death or serious injury.

1WARNING
DO NOT use front end components that have been remanufactured (straightened, plated, welded) in any way. There can be no certainty that remanufactured front end components will have the strength of the original, unchanged components. Using remanufactured components may lead to an accident which could result in death or serious injury.

1WARNING
The riders safety depends on the correct installation of this kit. USE THE APPROPRIATE SERVICE MANUAL PROCEDURES. If the procedure is not within your capabilities or if you do not have the correct tools, have your Harley-Davidson Dealer perform the installation. Improper installation could result in death or serious injury.

1WARNING
FXSTSB model motorcycles were NOT designed for sidecar use. The FXSTSB Springer fork was NOT designed for sidecar use. DO NOT use either the motorcycle or any FXSTSB Springer fork equipped vehicle with a sidecar. Use of any FXSTSB Springer fork equipped vehicle with a sidecar may lead to an accident which could result in death or serious injury.

1WARNING
Harley-Davidson has designed and manufactured this front end according to our very stringent and well-tested standards. Modifying the FXSTSB Springer front end in any way that changes our original design may lead to an accident which could result in death or serious injury.

INSTALLATION Bearing Races and Fork Assembly

Refer to the applicable Service Manual for Bearing Race and Fork Assembly procedures.

1WARNING
The components of your FXSTSB Springer front end and their design relationship to each other are very important. Altering these relationships by modifying the FXSTSB Springer front end could adversely affect the handling of the motorcycle which could result in death or serious injury.

Lower Springer
Refer to the applicable Service Manual for Lower Springer Assembly and Installation procedures.

1WARNING
Do not install this front end kit on any non-approved motorcycle. Do not install on three-wheeled vehicles of any kind. Installation of the FXSTSB Springer front end on anything other than Softail models could result in death or serious injury.

Springer Steering Head Bearing Adjustment

Refer to the applicable Service Manual for Springer Steering Head Bearing Adjustment procedures.

Headlamp
Refer to the applicable Service Manual for Headlamp Assembly and Installation procedures.

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Service Parts, Page 3 (Illustration 1) Legend

Illustration 1. Spring and Rigid Fork Components Subassemblies P/N 46190-00 (FXSTSB) ITEM DESCRIPTION 1 Nut, acorn (4) 2 Lockwasher 3 Washer (5) (See Illustration 2 also) 4 Decal, shock 5 Washer, spring rod (2) 6 Reflector, right side amber 7 Reflector, left side amber (not shown) 8 Front shock absorber 9 Spring bridge 10 Retainer, spring upper (2) 11 Cups, rebound spring (2) 12 Spring cup, compression spring (2) 13 Spring, compression outer (2) 14 Spring, compression inner (4) 15 Upper springs (2) 16 Seat, spring (4) 17 Travel bumper (4) 18 Bushing, spring rod (2) 19 Assembly, spring fork 20 Assembly, rigid fork 21 Nut, acorn, lower spring rod (2) 22 Spring rod, lower (2) 23 Spring rod, upper (2) 24 Screw 25 Label, spring bridge 26 Rubber bumper 27 Shock label Illustration 1. Spring, Rigid Fork and Riser Components Subassembly P/N 46206-00 (FXSTSB) ITEM DESCRIPTION 28 Screw (2) 29 Nut, acorn 30 Washer, rubber 31 Riser (2) 32 Cap (2) 33 Rubber bushing (4) 34 Bearing adjuster 35 Bolt, riser (2) 36 Upper triple clamp 37 Pinch bolt 38 Screw 39 Clip, throttle cable 40 Clip, brake line (2) 41 Cable tie (2) 42 Cable tie (4) 43 Washer 44 Clamp 45 Ground spring 46 Washer (2) 47 Capscrew (4) 48 Locknut (2) 49 Nut 50 Screw 51 Dust shield 52 Bearing, upper

PART NO. 7680W 7232 6812 66030-88 6353 59289-92 59290-92 54483-88A 46062-88 46060-88 46057-88 46056-88 46055-88 46054-88 46053-88 45937-88 45936-88 45935-88 45612-95 45600-95A 45567-88 45566-88 45543-88 3533 14192-88 11456 54329-97

PART NO. 855B 7959 6829 56546-95 56547-95 53156-86 48306-88 45544-88 45485-95 4350A 3538 10190 10076 10065 10006 6703 41713-86 46059-90 6753 3494A 7768W 7531 3594 48361-80 48345-60

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Service Parts
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Kit Number 46196-00

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FXSTSB (Springer) Front End Kit

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40 38 3

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N T O R SO MO I VD HARLEY-DA
E CY C L S

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Illustration 1. Spring and Rigid Fork Components-Subassemblies P/N 46190-00 and P/N 46206-00

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Service Parts

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FXSTSB (Springer) Front End Kit

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NOTE Only listed components are included in Subassembly Kits P/N 46190-00 and P/N 46206-00. All others shown for reference purposes only. 3

70 Fender 56 65 73 68 69 71 67

70

66

61 62 54 53 54

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58 59 60 Axle and Caliper Components included in Wheel and Brake Kit P/N 43849-00

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Illustration 2. Lower Fork Components-Subassembly Kits P/N 46190-00 and P/N 46206-00 Subassembly Kit P/N 46190-00 ITEM DESCRIPTION 53 Ball, spherical bearing (4) 54 Race, spherical bearing (4) 55 Bearing, spherical (2) 56 Locknut 57 Nut, acorn (4) 58 Pivot stud, rigid fork to rocker (2) 59 Washer (4) 60 Pivot stud, spring fork to rocker (2) 61 Jam nut, bearing retainer (2) 62 Bearing retainer, rigid fork (2) 63 Front rocker, right 64 Front rocker, left (not shown) 65 Link, brake reaction Subassembly Kit P/N 46206-00 ITEM DESCRIPTION 66 Locknut 67 Nut, shaft 68 Washer 69 Washer 70 Cotter pin (2) 71 Screw, brake link to bracket 72 Assembly bracket, caliper mounting 73 Spacer, rubber (3) (See Illustration 3 also)

PART NO. 9141 9140 9139 7667 7627 45684-90 45662-88 45683-90 45659-88 45655-88 45646-95 45647-95 41040-88B

PART NO. 7667 7588 6498 6371 534 4747 44044-00 11244

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Service Parts
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FXSTSB (Springer) Front End Kit

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84 80 74 80 84 NOTE Fender NOT included in Kit. Only listed components are included in Subassembly Kits P/N 46190-00 and P/N 46206-00. All others shown for reference purposes only.

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79 76 81 85

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83 Bearing must be pressed into fender Illustration 3. Headlamp and Fender Components-Subassembly Kits P/N 46190-00 and P/N 46206-00 Subassembly Kit P/N 46190-00 ITEM DESCRIPTION 74 Bracket, headlight mounting 75 Bolt 76 Pivot screw (2) PART NO. 67892-93 3214 2738 Subassembly Kit P/N 46206-00 ITEM DESCRIPTION 77 Nut (2) 78 Assembly, headlight 79 Washer (2) 80 Rubber washer (2) 81 Insert, fender (2) 82 Pivot link (2) 83 Bearing 84 Screw (2) 85 Screw (2) PART NO. 7531 67841-00 6409 6379W 59043-93 41042-93 33714-90A 2917 2723

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