Table of Contents

This is an old revision of the document!

EVO: Suspension

Sub-Documents

* . . . 2014 XL1200T Front Fork Testing w/ Spring Rate Charts

* . . . 1994 XLH Front Forks Disassembled - Measurements w/Pictures

* . . . 1200S Fork Rebuild & Hyperpro Spring Fitment

* . . . 1200S Suspension: Settings

* . . . Future Subject

* . . . Future Subject


Front Fork Info

The front forks on most Sportster models consists of two tubes - A slider tube that is mounted in the triple-trees and a lower leg tube into which the slider tube compresses. Each slider/leg assembly has an internal compression spring and damper tube. The spring supports the weight of the rider & bike, collapsing or expanding to cushion the ride over bumps and cavities in the road surface. The damper tube is submerged in oil and uses the passage of oil between internal chambers to help control the speed with which the slider/leg assembly compresses together & expands apart as it cushions the ride. Because the damper tube is attached to the lower leg, the length of the damper tube determines the amount of 'travel' the slider tube has within the lower leg.

In addition to the internal physical spring, there is an 'air spring' effect caused by the amount of air above the oil level in the fork assembly.

Functionally, there must be enough fork oil to fully submerge (engulf) the damper tube during its entire operational movement. The MoCo specified oil amount still leaves an air pocket above the level of the oil in the fork.

The air captured between the top of the oil level and the fork caps (which are sealed) creates an 'air spring' by which the compression of the air during fork compression helps the physical spring prevent total collapse of the fork, while also assisting the spring in expanding the fork after a compression event. The size of the air pocket, measured by determining the exact distance the top of the oil is from the top of the slider tube, can be varied (by adding or reducing oil) to produce a stronger or weaker 'air spring' effect (but the adjusted oil level must still allow the damper tube to be fully submerged during its entire operational movement).

Here's an example of the parts for that design (1994 Sportster XLH):


1986-2003 Forks (Except 1200S)

Abbreviations:

  • Std = 883 Standard Model & 1200 Standard Model
  • Dlx = 883 Deluxe Model
  • Hug = 883 Hugger Model
  • Ctm = 883 Custom Model & 1200 Custom Model

Slider Tube, Damper Tube & Spring

1986 Late Std & Dlx
-198735mm TubesStd & Dlx & HugLength
Slider Tube45407-8623.25“
Damper Tube45913-84
Spring-#Coils45907-8320.25”
1988-199139mm Tubes Std & Dlx & HugLength
Slider Tube45381-8723.375“
Damper Tube45925-8810.875”
Spring-#Coils45376-8720.25“
1992Models »Std&DlxLengthHuggerLength
Slider Tube45381-8723.375”45395-9224.25“
Damper Tube45925-8810.875”45938-927.5“
Spring-#Coils45376-8720.25”45372-9221.5“_47coils
1993
Slider Tube45381-8723.375”45395-9224.25“
Mid-yearSlider Tube45395-9224.25” ● ●
Damper Tube45925-8810.875“45938-927.5”
Spring-#Coils45376-8720.25“45372-9221.5”_47coils
1994-1995
Slider Tube45395-9224.25“45395-9224.25”
Damper Tube45925-949.50“45938-927.5”
Spring-#Coils45376-9421.5“_53coils45372-9221.5”_47coils
1996Models »StdLengthHug&CtmLength
Slider Tube45395-9224.25“45395-9224.25”
Damper Tube45925-949.50“ 45938-927.5”
Spring-#Coils45376-9421.5“_53coils45372-9221.5”_47coils
1997-1998
Slider Tube45395-9723.375“ 45395-9224.25”
Damper Tube45925-979.0“45938-927.5”
Spring-#Coils45376-97 45372-9221.5“_47coils
1999-2003Models »Std&CtmLengthHuggerLength
Slider Tube45395-9723.375”45395-9224.25“
Damper Tube45925-979.0”45938-927.5“
Spring-#Coils45376-97 45372-9221.5”_47coils

Slider Lower Legs (Except 1200S)

Model(s)Lower Sliders
Left Leg		Lower Sliders
Right Leg
1984-1987 1)2)All45912-8445906-84
1988-1999 3) 4)
5) 6) 7) 8) 9) 		All45921-8745923-87
2000-2003 10) 11)
12)13)		All
(Except 883R) 		45921-0045923-00
2002-2003 14)15)XL883R45921-0045922-00



1996-2003 Forks For 1200 Sport Model

XL1200S Sport Model - Fork Parts

See also Setting up the 1200S Suspension

Fork Parts Length
1996-2003Slider Tube45366-96
Cartridge Damper Tube46024-96
Cartridge Spring-#Coils45367-96

Slider Lower Legs

Model(s)Lower Sliders
Left Leg		Lower Sliders
Right Leg
1996-1999 16) 17) 18) 19) XL1200S46023-9646022-96
2000-2003 20) 21)22)23)XL1200S46023-0046022-00


Draining 1200S Forks

  • 1200S sliders don't have drain plugs. So, here is one way of doing so. 24)
  • Basically, once you have the forks out of the bike, remove the large top nut (loosen it slightly while you have the forks clamped in the lower triple tree, (as shown here Part 4 Dismantle the Forks ) while holding the slider. There is no spring pressure on this nut, so it's easy. 25)
  • The slider will drop away, but don't let it drop more than a couple of inches or you'll have oil pouring out and not know how much has come out. 26)
  • Carefully tip the fork upside-down and pour the oil into a clear measuring container (a wide funnel will help you to not lose any). 27)
  • Bring the fork upright and pull the slider to the very top again, pump the fork a few times to empty the damper tube, then turn it upside-down again and pour more oil into your measuring container. Repeat this a couple more times to get as much of the old oil out as possible. 28)
  • Check how much oil came out of the fork, make a note of it, then pour the old oil into a waste container. 29)
  • Measure the same quantity of fresh oil into the measuring container, then, with the slider still close to the top of its stroke, carefully pour the oil into it. You're pouring the oil between the coils of the spring, so you need to go slowly and keep the fork vertical to avoid losing any. If you can get your hands on a funnel and fit a narrow flexible hose to the end of it, it may make things easier. 30)
  • When all the fresh oil is in, thread the slider onto the top nut again; clamp the fork into the bottom triple tree only to hold it steady while you fully tighten the top nut; then push the fork all the way to the top again and clamp it in place. 31)
  • Repeat on the other fork. 32)


2004-later Forks

  • Be careful, with the Low bikes, taking out the shock caps. There is about 2 1/2 “ of spring preload so the cap wants to come out in a hurry. I am about 200 lbs and fairly strong and it was about all I could do to reinstall the caps with a 1 3/8 socket on a 6” extension on a ratchet. 33)

Damper Tube Forks

Models Slider TubeDamper TubeSpring Notes
2004-2008 04-08 883/C 1200C/R
05-08 883R
07 XL50 Annv
08 1200L 		45395-0445925-0445376-04DT=9.0“ - 45925-04
2005-2006 883L 46218-0545938-9246267-05DT=7.5” - 45938-92
2007 883L 46218-0547313-0747299-07DT=7.0“ - 47313-07 w/ 2-holes 8.92mm
2007-2012 1200N 46218-0547313-0747299-07DT=7.0” - 47313-07 w/ 2-holes 8.92mm
2008 883L 45395-0447313-0747299-07DT=7.0“ - 47313-07 w/ 2-holes 8.92mm
2009 883 1200R 45395-0945925-0945376-09DT=7.5” - 45925-09
2009-2010 883C/R 1200C 45395-0945925-0945376-09DT=7.5“ - 45925-09
2009-2010 883L/N 46218-0547313-0747299-07DT=7.0” - 47313-07 w/ 2-holes 8.92mm
2009-2011 1200L 46218-0545938-9246267-05DT=7.5“ - 45938-92
2010-2015 1200X (48) 45395-091062710417
2011-2015 883R 45395-0945925-0945376-09DT=7.5” - 45925-09
2011-2015 883L 46218-0545938-9246267-05DT=7.5“ - 45938-92
2011-2013 883N 46218-0547313-0747299-07DT=7.0” - 47313-07 w/ 2-holes 8.92mm
2011-2015 1200C/CP 45395-0945458-0946245-09
2013 1200C - Annv 45395-0945458-0946245-09
2013-2015 1200 CA/CB 45395-0945458-0946245-09
2013-2015 1200V (72) 45395-0945925-0945500142DT=7.5“ - 45925-09
2014-2015 883N 46218-0547313-0745500139DT=7.0” - 47313-07 w/ 2-holes 8.92mm
2014-2016 1200T 45395-0945458-0945500244

(Measurements for this section contributed by XLForum members)

Mixed-Tech Forks

Models Rt SliderRt DamperRt SpringLt SliderLt CartrdgLtSpring
2016 1200CA 45500281 45500278 45500275 45500280 45500282 45500274
2016 1200CP 45500281 45500278 45500275 45500280 45500282 45500274
2016-2017 1200CB 45500281 45500278 45500275 45500280 45500282 45500274
2016-2018 883L 45500281 45500278 45500275 45500280 45500282 45500274
2016-2018 883N 45500281 45500302 45500301 45500280 45500304 45500300
2016-2018 1200C 45500281 45500278 45500275 45500280 45500282 45500274
2016 1200X (48) 45500281 45500302 45500301 45500280 45500304 45500300
2016 1200V (72) 45500281 45500279 45500277 45500280 45500283 45500276
2017-2018 1200X (48) 45500295 45500298 45500294 45500295 45500296 45500293
2018 1200X (48 Annv) 45500295 45500298 45500294 45500295 45500296 45500293
2018 ?
?

Inverted Forks

Inverted Forks use an upper slide tube that is the larger, outer tube while the lower, inner slider tube is used to attach the wheel. This is upside-down from the traditional damper tube design.

Models Upper Left Fork Right Fork Notes
Models Outer Tube Cart/RodSpring RodSpring Notes
2008-2009 XR 1200 46884-0846878-0846882-0846359-0646882-08Lt uses Cart/Sprg - Rt uses Rod/Sprg
2010 XR 1200 &
XR 1200X 		10628 46681-101041846681-101041846681-10 is Compl. Rod Assy (each side)
2011-2013 XLR 1200X 10628 46681-101041846681-101041846681-10 is Compl. Rod Assy (each side)
2016 XL1200CX Roadster 4550035845500371455003694550036145500369Lt uses Cart/Sprg - Rt uses Rod/Sprg
?
?

Slider Lower Legs

Model(s)Lower Sliders
Left Leg		Lower Sliders
Right Leg		 Rt Brk
Mount 		Notes
2004 34)883/883C/1200C45921-0045923-00 ?
2004-200735) 36)37)38)1200R45921-0045922-00
2005-200639)40)883/883L
883C/1200C		45921-0045923-00 ?
2005-200741)42)43)883R46450-0546449-05 ?
2007 44)All except 883R
1200R/1200N		45921-0045923-00 ?
200745)1200N48726-0748716-07 ?
2008 46)All except 883R
1200R/1200N		46075-0446076-04 ?
2008-2013 47)48)49)50)51)52)883R46450-0846449-08 ?
2008-2009 53)54)1200R46075-0445922-08 ?
2008-2012 55)56)57)58)59)1200N48726-0848716-08 ?
2008-201060)61)XR120046880-0846879-08 YES Inverted Forks
2009 62)883/883C/883L
1200C/1200L		46075-0446076-04 ?
2009-2014 63)64)65)66)67) 68)883N48726-0848716-08 ?
2010 69)883C/883L
1200C/1200L		46075-0446076-04 ?
2010-2015 70)71)72)73) 74) 75)XL1200X48850-1048849-10 ?
2010-2013 76) 77)78)79) 80)XR1200X48786-1048785-10 YES Inverted Forks
2011 81)1200L46075-0446076-04 ?
2011-2016 82)83) 84) 85) 86)87)883L49401-1149403-11 ?
2012 88)1200C/1200CP49411-1149412-11 ?
2013 89)1200V46075-0446076-04 ?
2013 90)1200C/1200C Anv
1200CP/1200CA/1200CB		49411-1149412-11 ?
2014-2016 91) 92) 93)1200V4550005645500075 ?
2014-2015 94) 95)883R4550005545500076 ?
2014-2016 96) 97) 98)1200C/1200CP
1200CA/1200CB		49411-1149412-11 ?
2015-2016 99) 100)883N4550005445500057 ?
2015-2016 101) 102)1200T49401-1149403-11 ?
2016 103)XL1200X4550028745500290 ?
2016-2018 XL1200CX Roadster4550035945500360 YES Inverted Forks

Reference Additional Information on the 2004+ models in these XLForum Threads:
http://xlforum.net/vbportal/forums/showpost.php?p=3265511
http://xlforum.net/vbportal/forums/showthread.php?t=1827354
http://xlforum.net/vbportal/forums/showthread.php?t=1085901
http://xlforum.net/vbportal/forums/showthread.php?t=1971682


Fork Oil Drain Screws

45790-80 - Stock Philips-head Drain Screw with Washer (Requires 1 for each fork)

  • (Starting in 2008, some models do not have fork oil drain screws)

45815-03 - Chrome Fork Slider Drain Screw Kit104)
Screw size is M4 (0.7mm) × 6mm - Includes a pair of chrome allen head drain screws and washers - Uses 2.5mm allen key



1)
1979-1985 HD Sportster Parts Catalog pg 83,85
2) , 3)
1986-1990 HD Sportster Parts Catalog pg 65
4)
1991-1992 HD Sportster Parts Catalog pg 65
5)
1993-1994 HD Sportster Parts Catalog pg 61
6)
1995-1996 HD Sportster Parts Catalog pg 61
7) , 17)
1997 HD Sportster Parts Catalog pg 61
8)
1998 HD Sportster Parts Catalog pg 63
9)
1999 HD Sportster Parts Catalog pg 67
10)
2000 HD Sportster Parts Catalog pg 67
11)
2001 HD Sportster Parts Catalog pg 69
12) , 14)
2002 HD Sportster Parts Catalog pg 69
13) , 15)
2003 HD Sportster Parts Catalog pg 69
16)
1995-1996 HD Sportster Parts Catalog pg 63
18)
1998 HD Sportster Parts Catalog pg 65
19)
1999 HD Sportster Parts Catalog pg 69
20)
2000 HD Sportster Parts Catalog pg 69
21)
2001 HD Sportster Parts Catalog pg 71
22)
2002 HD Sportster Parts Catalog pg 71
23)
2003 HD Sportster Parts Catalog pg 71
24) , 25) , 26) , 27) , 28) , 29) , 30) , 31) , 32)
steelworker http://xlforum.net/vbportal/forums/showthread.php?t=744608&page=6
33)
whittlebeast http://xlforum.net/vbportal/forums/showthread.php?t=47542&highlight=1200s+shocks&page=5
34) , 35)
2004 HD Sportster Parts Catalog pg 67
36) , 39) , 41)
2005 HD Sportster Parts Catalog pg 71
37) , 40) , 42)
2006 HD Sportster Parts Catalog pg 71
38) , 43) , 44) , 45)
2007 HD Sportster Parts Catalog pg 71
46) , 47) , 53) , 55)
2008 HD Sportster Parts Catalog pg 71
48) , 54) , 56) , 62) , 63)
2009 HD Sportster Parts Catalog pg 109
49) , 69) , 70)
2010 HD Sportster Parts Catalog pg 103
50) , 71) , 81) , 82)
2011 HD Sportster Parts Catalog pg 103
51) , 72) , 83) , 88)
2012 HD Sportster Parts Catalog pg 103
52) , 73) , 79) , 84) , 89) , 90)
2013 HD Sportster Parts Catalog pg 115
57) , 64)
2010 HD Sportster Parts Catalog pg 105
58) , 65)
2011 HD Sportster Parts Catalog pg 105
59) , 66)
2012 HD Sportster Parts Catalog pg 105
60)
2009 HD Sportster Parts Catalog pg 111
61)
2010 HD Sportster Parts Catalog pg 107
67)
2013 HD Sportster Parts Catalog pg 117
68) , 74) , 80) , 85) , 91) , 94) , 96)
2014 HD Sportster Parts Catalog pg 81
75) , 86) , 92) , 95) , 97) , 98) , 101)
2015 HD Sportster Parts Catalog pg 81
76)
2010 HD Sportster Parts Catalog pg 109
77)
2011 HD Sportster Parts Catalog pg 107
78)
2012 HD Sportster Parts Catalog pg 107
87) , 93) , 102)
2016 HD Sportster Parts Catalog pg 81
99)
2015 HD Sportster Parts Catalog pg 83
100)
2016 HD Sportster Parts Catalog pg 87
103)
2016 HD Sportster Parts Catalog pg 85
104)
Folkie - xlforum.net/vbportal/forums/showthread.php?t=738626
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