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Scott
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Discussion Starter #1
Thanks everyone for your help.


Software:


____ Service Manual - H-D Part #99501-___ <-Your bike's year here

____ Parts Book - H-D Part #99457-___ <-Your bike's year here

____ Anti-Seize (4oz bottle) for the axles & pivot shafts and LOWER Shock bolt

____ Blue Locktite - Axles & Pivot Head nuts and TOP Shock bolt

____ Blue Painters Tape (2" wide) to tape off all areas (sprocket, forks, swing-arm, etc.) to avoid scratches

____ Short Bungee Cords (3) to hold front & rear brake calipers

____ Black Fine Sharpie Marker & Note paper to keep track of parts & what side they came from

____ Packet of Shop Towels

____ Container of Latex, or similar, Gloves



Hardware:


____ Bike Lift WITH STRAP DOWNS!!!

____ Lift Jack to hold/secure and lower/raise the rear/front tires

____ Torque Wrench able to torque to 150 FT/LBS

____ Assorted TORX & Metric Hex Allen Wrench Sets for Rotor & Compensator Bowl Fasteners

____ Magnetic Tray to hold & organize fasteners in one place


Shocks & Rear Tire Removal

____ 24mm (2002-2004) or 36mm (2005 & up) Socket for Rear Axle Nut and Assembly Bolt

____ 8mm hex bit for lower shock bolts - other models

____ Male torx tools for lower shock bolts - 6 point Torx (T-50) on 2007 DX models

____ Reverse-pliers for Retaining Ring removal

____ Rubber mallet for rear axle removal


Brake Pads Replacement

Do not remove caliper banjo bolts AT ALL - Level of difficulty will increase if this is done!

____ Brake Pads - Lyndalls or others

____ 10mm 12pt. Socket for Caliper Mounting Bolts

____ 1/4" 12pt. Socket for Brake Pad Bolts

____ Rolled-up Beach/Shower Towel to place between Front Brake Lever & Hand grip


Front Tire Removal

____ 24mm Socket for Axle Nut - Left side

____ 7/16" Drill Bit, Screwdriver or Metal Rod for axle nut re-install


Swing Arm Removal

____ 30mm Socket for Hex Pivot Shaft Nut - Thin Walled Socket NOT Impact-type

____ 9/16th or 14mm hex bit for the hex head in the Pivot Shaft Assembly

____ Small adjustable wrench for brake line guides removal

____ Belt Tension tool - H-D Part #40006-85



Miscellaneous:

____ Mothers Aluminum/Chrome Polish & PowerBall Mini - www.mothers.com

____ ZoopSeal Jr. Protective Sealer Kit - www.zoopseal.com

____ Chrome Hardware Kit - Headlamp & Front Fender - H-D Part #94013-03

____ Chrome Shock Hardware Kit - H-D Part #54013-04

____ Rear Axle Cover Kit - H-D Part #45621-02

____ New Progressive 440's Shocks or others __________________________________

____ Chrome Rotor Hardware Kits __________________________________

____ Chrome Rear Wheel Spacer Kit __________________________________

____ Chrome Front Wheel Spacer Kit __________________________________

____ New Passenger Foot Peg Mounts or Foot Boards __________________________________

____ New Custom/Chrome Swing Arm __________________________________

____ New Custom Belt Guards __________________________________

____ New Custom Sprocket __________________________________

____ New Custom Rotors __________________________________

____ New Custom Rims __________________________________

____ Beer (or Coffee for Max, if he shows up) & BBQ for helpers if not alone.


Notes:











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