This is an old revision of the document!
EVO: Suspension - Sub-01C
1994 XLH Front Forks Disassembled - Measurements w/Pictures
The following information was collected when the stock 1994 Front Forks
were disassembled to be cleaned and the internal springs were replaced
with a set of Progressive-brand progressively wound springs.
| Actual Measurements from a 1994 Std Model Sportster Front Fork | |
|---|---|
| Slider Tube Length (45395-92) | 24.250in |
| 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:
Reference Additional Information on the 1986-2003 models in these XLForum Threads:
Thanks to jaystellato for contributing to this conversation:
http://xlforum.net/vbportal/forums/showthread.php?t=2004931
http://xlforum.net/vbportal/forums/showthread.php?t=1971682
