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techtalk:evo:susp01c [2019/08/18 19:53] – [1994 XLH Front Forks Disassembled - Measurements w/Pictures] ixl2relaxtechtalk:evo:susp01c [2024/01/06 05:09] (current) – hippysmack
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 ===== 1994 XLH Front Forks Disassembled - Measurements w/Pictures ===== ===== 1994 XLH Front Forks Disassembled - Measurements w/Pictures =====
  
-The following information was collected when the stock 1994 Front Forks\\ +The following information was collected when the stock 1994 Front Forks were disassembled to be cleaned\\ 
-were disassembled to be cleaned and the internal springs were replaced\\ +and the internal springs were replaced with a set of Progressive-brand progressively wound springs.
-with a set of Progressive-brand progressively wound springs.\\+
  
-^Actual Measurements from a 1994 Std Model Sportster Front Fork|| +The following tips from the XLF threads were especially helpful:\\ 
-|Slider Tube Length (45395-92)|  24.250in| +1) Loosen (not remove) the Damper Bolts (6mm Allen Key) while the forks are still on the bike & under spring tension\\ 
-|Slider Outside Diameter |  1.532in| +2) Remove the Fork Caps using a 1-3/8" Socket (or 35mm).\\ 
-||| +3) Align the fork cap on the slider tube (no springs installed) and mark the exact point (on both the cap and the slider)\\\ 
-|Leg Length (45921-87 -or- 45923-87)| 16.375in| +.... where the threads begin to engage - This tip was extremely helpful in getting the cap back on while compressing the spring.\\ 
-|Leg Asbl'd Length- To Top of Cap |  17.125in| +4) Use a 1-1/2" PVC coupling for the fork seal driver (coupling center spline removed)\\ 
-||| +\\
-|Spring Length (45376-94)| 21.500in| +
-|Spring Outside Diameter |  1.190in| +
-|Spring - Number of Coils | 53| +
-|Spring Coil Wire Diameter |  .180in| +
-|Spring Single Rate - Gap |  .242in| +
-||| +
-|Spring Protrudes out of Slider (Fork Ext'd) |  1.375in| +
-|(no preload spacer used)|| +
-||| +
-|Damper Tube Length (45925-94)|  9.500in| +
-|Damper Tube Outside Diameter |  .715in| +
-|Damper Tube Head OD |  1.175in| +
-|Damper Tube Holes (4) Diameter |  .298in| +
-||| +
-|Top Out Spring Length (45374-87)|  1.890in| +
-|Top Out Spring Outside Diameter |  1.20in| +
-|Top Out Spring - Number of Coils | 7| +
-|Top Out Spring Coil Wire Diameter |  .196in| +
-|Top Out Spring Single Rate - Gap |  .130in| +
-||| +
-| | | +
-|Assembled Fork|| +
-|Top of Damper Tube to Top of Slider (no cap) (Fork Comp'd)|  14.438in| +
-||| +
-| | | +
-|  Top of Leg Cap to Top of Slider (Fork Ext'd)|  15.125in| +
-|  Top of Leg Cap to Top of Slider (Fork Comp'd)|  9.563in| +
-|  Therefore -> Maximum Full Travel Equals|  5.562in|+
  
-Pictures from a disassembled 1994 Front Fork:\\+ 
 +^Actual Measurements from a 1994 Std Model Sportster Front Fork||| 
 +|Slider Tube Length (45395-92)|  24.250in|{{ :techtalk:evo:susp:forks-dampersuspparts-simpleillustration.jpg?150| }}| 
 +|Slider Outside Diameter |  1.532in|:::| 
 +|||:::| 
 +|Leg Length (45921-87 -or- 45923-87)| 16.375in|:::| 
 +|Leg Asbl'd Length- To Top of Cap |  17.125in|:::| 
 +|||:::| 
 +|Spring Length (45376-94)| 21.500in|:::| 
 +|Spring Outside Diameter |  1.190in|:::| 
 +|Spring - Number of Coils | 53|:::| 
 +|Spring Coil Wire Diameter |  .180in|:::| 
 +|Spring Single Rate - Gap |  .242in|:::| 
 +|||:::| 
 +|Spring Protrudes out of Slider (Fork Ext'd) |  1.375in|:::| 
 +|(no preload spacer used)||:::| 
 +|||:::| 
 +|Damper Tube Length (45925-94)|  9.500in|:::| 
 +|Damper Tube Outside Diameter |  .715in|:::| 
 +|Damper Tube Head OD |  1.175in|:::| 
 +|Damper Tube Holes (4) Diameter |  .298in|:::| 
 +|||:::| 
 +|Top Out Spring Length (45374-87)|  1.890in|:::| 
 +|Top Out Spring Outside Diameter |  1.20in|:::| 
 +|Top Out Spring - Number of Coils | 7|:::| 
 +|Top Out Spring Coil Wire Diameter |  .196in|:::| 
 +|Top Out Spring Single Rate - Gap |  .130in|:::| 
 +|||:::| 
 +|  ||:::| 
 +|Assembled Fork||:::| 
 +|Top of Damper Tube to Top of Slider (no cap) (Fork Comp'd)|  14.438in|:::| 
 +|||:::| 
 +|  ||:::| 
 +|  Top of Leg Cap to Top of Slider (Fork Ext'd)|  15.125in|:::| 
 +|  Top of Leg Cap to Top of Slider (Fork Comp'd)|  9.563in|:::| 
 +|  Therefore -> Maximum Full Travel Equals|  5.562in|:::| 
 +\\ 
 + 
 +**Pictures from a disassembled 1994 Front Fork:**\\
 {{:techtalk:evo:susp:1994-std-fork-parts-01.jpg?800|}}\\ {{:techtalk:evo:susp:1994-std-fork-parts-01.jpg?800|}}\\
 {{:techtalk:evo:susp:1994-std-fork-parts-02.jpg?400|}} {{:techtalk:evo:susp:1994-std-fork-parts-02.jpg?400|}}
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 Reference Additional Information on the 1986-2003 models in these XLForum Threads:\\ Reference Additional Information on the 1986-2003 models in these XLForum Threads:\\
 Thanks to jaystellato for contributing to this conversation:\\ Thanks to jaystellato for contributing to this conversation:\\
-http://xlforum.net/forums/showthread.php?t=2004931\\ +https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-suspension-frame-forks-handlebars-fuel-tank-oil-tank-fenders/188025-rigid-mount-fork-info?t=2004931\\ 
-http://xlforum.net/forums/showthread.php?t=1971682\\+https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-suspension-frame-forks-handlebars-fuel-tank-oil-tank-fenders/183137-wrong-damper-tubes?t=1971682\\
  
 All Photos are from IXL2Relax at the XLForum All Photos are from IXL2Relax at the XLForum
  
 Here's the Progressive Springs Upgrade thread by IXL2Relax at the XLForum: Here's the Progressive Springs Upgrade thread by IXL2Relax at the XLForum:
-http://xlforum.net/forums/showthread.php?t=2006111+https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-suspension-frame-forks-handlebars-fuel-tank-oil-tank-fenders/188361-progressive-fork-springs-11-1527?t=2006111
  
 \\ \\

Trace: • EVO: Suspension - Sub-01C