Differences

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--- techtalk:evo:susp01 [2019/02/21 00:18]
ixl2relax [1986-2003 Forks (Except 1200S)]
+++ techtalk:evo:susp01 [2022/05/20 22:41]
ixl2relax [1986-2003 Forks (Except 1200S)]
@@ Line 2: / Line 2: @@
 ====== EVO: Suspension ======
+Check the REFerence Section for additional Suspension information:\\
+[[techtalk:ref:tools010#suspension|Suspension Tools]]
 ===== Sub-Documents =====
@@ Line 42: / Line 45: @@
 The set of damper tubes on the left includes the 'top out' springs which help cushion the end of travel when the forks expand. All models use the same top out springs (as stock).
-Racetech has a fairly detailed explanation of Damper Rod Forks, along with their promotion of cartridge emulators, at this site: http://racetech.com/html_files/dampingrodforks.html
+Racetech has a fairly detailed explanation of Damper Rod Forks, along with their promotion of cartridge emulators, at this site: https://racetech.com/page/title/Emulators-How%20They%20Work
 \\
+**TIPS**
+The 39mm Fork Caps (which are 6-pointed) need a 1-3/8"(1.375") 6-point socket or Cap Wrench. A usable equivalent is a 35mm(1.378") size. It's a good idea to wrap masking tape, electrical tape or duct tape (depending on the thickness of the tape) around the chrome cap to protect if from marks. ((See this XLForum Thread: http://xlforum.net/forums/showthread.php?t=675643))
+Use a 6-point socket, rather than a 12-point version, to lessen the chance of rounding the points on the cap. This is also why an adjustable wrench should be avoided.
+Loosen (not remove) the Damper Bolts (6mm Allen Key) while the forks are still on the bike so the spring tension can help hold the Damper Tube (internal) from rotating while loosening the bolt.
+For reassembly, prepare the fork cap by aligning it with the slider tube (no springs installed) and mark the exact point (on both the cap and the slider) where the threads begin to engage - This is extremely helpful in getting the cap back on while compressing the spring.
+Use a 1-1/2" PVC coupling for the fork seal driver (coupling center spline removed).
 \\
+===== Fork Oil Drain Screws =====
+-80 - Stock __JIS-head__ Drain Screw with Washer (Requires 1 for each fork)\\
+    * (Starting in 2008, some models do not have fork oil drain screws)
+    * (Use a JIS screwdriver for JIS screws. JIS screws look like Philips screws with a dot in the center of the head, but the JIS version is a wider blade with different spline angles. Using a Philips screwdriver on a JIS screw will often round out the screw head. However, using a JIS screwdriver on a Philips-head screw may work just fine, since the driver splines fit snugly on the upper, heavier part of the screw head.)
+-03 - Chrome Fork Slider Drain Screw Kit ((Folkie of the XLFORUM xlforum.net/forums/showthread.php?t=738626))\\
+Screw size is M4 (0.7mm) × 6mm - Includes a pair of chrome allen head drain screws and washers - Uses 2.5mm allen key. \\
+(Try a 3mm allen key first, the chroming takes up some space in the hex slot) \\
+You can also upgrade to socket head (Allen head) bolts to help prevent stripping out heads.  \\
+These are stainless steel bought from a hardware store. Size M4 (0.7mm) × 8mm. \\
+{{:techtalk:evo:susp:fork_drain_screw_upgrade_pic1_by_luxblue.jpg?direct&400|}} ((photo by LuxBlue of the XLFORUM http://xlforum.net/forums/showthread.php?t=1056600)) {{:techtalk:evo:susp:fork_drain_screw_upgrade_pic2_by_luxblue.jpg?direct&400|}} ((photo by LuxBlue of the XLFORUM http://xlforum.net/forums/showthread.php?t=1056600)) \\
+\\
 \\
@@ Line 89: / Line 124: @@
 | |Slider Tube|45395-97|23.375" |45395-92|24.25"|
 |:::|Damper Tube|45925-97|9.0"|45938-92|7.5"|
-|:::|Spring-#Coils|45376-97| |45372-92|21.5"_47coils|
+|:::|Spring-#Coils|45376-97|20.5"_DR|45372-92|21.5"_47coils|
 |   |   |   |   |   |   |
 ^1998|Models >>^Std|Length^Hug&Ctm|Length|
 | |Slider Tube|45395-97|23.375" |45395-92|24.25"|
 |:::|Damper Tube|45925-97|9.0"|45938-92|7.5"|
-|:::|Spring-#Coils|45376-97| |45372-92|21.5"_47coils|
+|:::|Spring-#Coils|45376-97|20.5"_DR|45372-92|21.5"_47coils|
 |   |   |   |   |   |   |
 ^1999-2003|Models >>^Std&Ctm|Length^Hugger|Length|
 | |Slider Tube|45395-97|23.375"|45395-92|24.25"|
 |:::|Damper Tube|45925-97|9.0"|45938-92|7.5"|
-|:::|Spring-#Coils|45376-97| |45372-92|21.5"_47coils|
+|:::|Spring-#Coils|45376-97|20.5"_Dr|45372-92|21.5"_47coils|
 ^2002-2003|Models >>^883R|Length|   ||
 | |Slider Tube|45395-97|23.375"|   ||
 |:::|Damper Tube|45925-97|9.0"|   ||
-|:::|Spring-#Coils|45376-97| |   ||
+|:::|Spring-#Coils|45376-97|20.5"_DR|   ||
@@ Line 115: / Line 150: @@
 \\
-Spring Rates:
+Spring Notes/Rates:\\
 -92 - 21.5" - 47coils - Rate reported as 40#/in ((by sebasbecu at xlforum.net/forums/showthread.php?t=2072495))
+-97 - 20.5"_DR - These are dual-rate springs while most of the other fork springs are single-rate
@@ Line 191: / Line 226: @@
 ^ 2014-2018 | 1200T |45395-09|45458-09|45500244|DT=7.5" - 45458-09((xlforum.net/forums/showthread.php?t=1863121)) |
-(Measurements for this section contributed by XLForum members)
+(Measurements for this section contributed by XLForum member, including this thread: http://xlforum.net/forums/showthread.php?t=2045589)
 ===== Mixed-Tech Forks =====
@@ Line 206: / Line 241: @@
 ^ 2016      | 1200V (72) | 45500280 | 45500283 | 45500276 | 45500281 | 45500279 | 45500277 |
 ^ 2017-2018 | 1200X (48) | 45500295 | 45500296 | 45500293 | 45500295 | 45500298 | 45500294 |
+\\
+Here's a thread by 'Tomcatt' of the XLForum regarding changing to aftermarket springs & changing the oil viscosity/level in these mixed-tech forks:\\
+http://xlforum.net/forums/showthread.php?t=2073068
+\\
@@ Line 264: / Line 305: @@
 ====== Fork Service Kits ======
-The Fork Service Kit is a collection of the parts recommended to be replaced for refresh maintenance. It includes all the parts that function between the Upper Slide Tube and the Lower Slide Tube plus new damper/cartridge mounting screws & Fork Cap Seals (O-ring).
+The Fork Service Kit is a collection of the parts recommended to be replaced for refresh maintenance. It includes all the parts that function between the Upper Slide Tube and the Lower Slide Tube plus new damper/cartridge mounting screws & Fork Cap Seals (O-ring). Each kit will refresh ONE FORK TUBE.
 For the models that use the same Fork Service Kit, one might expect the upper & lower slide tubes to be functionally compatible across all years (that's an assumption - there might be something that IS incompatible - but unknown).
@@ Line 270: / Line 311: @@
 |                    ^  1988-2018  ^   2016+    ^   2016+ Inv Forks  |  Notes:            |
 | :::                ^ All Except >> ^  Model 48  ^  Roadster   |              |
-|Full Service Kit >> | 49378-09    | 45500307   | 49380-09  |              |
+|Full Service Kit >> | 49378-09    | 45500307   | 49380-09  |  FOR ONE FORK TUBE  |
 ^ Includes the following parts in the kits:    |||||
 |Slide Bushing       | 45465-87    | 46080-01   | 46348-06  | On Inner Slide Tube |
 |Dust Seal           | 45401-87    | 46512-01A  | J8130.3A8 | Into Outer Slide Tube |
 |Stopper Ring        | 45905-87    | 46513-01   | 45842-77A | Wire Retaining Clip |
-|Oil Seal            | 45378-87    | 46514-01A  | 12085     | Into Outer Slide Tube |
+|Oil Seal *          | 45378-87    | 46514-01A  | 12085     | Into Outer Slide Tube |
 |Seal Spacer         | 45377-87    | 46515-01   | 46346-06  | Into Outer Slide Tube |
 |Guide Bushing       | 45461-87    | 46516-01   | 46343-06  | Into Outer Slide Tube |
@@ Line 285: / Line 326: @@
 |Damper Rod Screw Rt |  N/A        |  45500118  |  N/A      |              |
 |Damper Rod Screw Lt |  N/A        |  45500236  |  N/A      |              |
+|  * Oil Seal is driven on Letter Side into Outer Slide Tube - Hollow Side in first |||||
-====== Fork Oil Drain Screws ======
--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)
--03 - Chrome Fork Slider Drain Screw Kit((Folkie - xlforum.net/forums/showthread.php?t=738626))\\
-Screw size is M4 (0.7mm) × 6mm - Includes a pair of chrome allen head drain screws and washers - Uses 2.5mm allen key
 \\

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