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--- techtalk:evo:susp01c [2017/11/05 17:26]
ixl2relax [1994 XLH Front Forks Disassembled - Measurements w/Pictures]
+++ techtalk:evo:susp01c [2021/07/16 23:41]
ixl2relax [1994 XLH Front Forks Disassembled - Measurements w/Pictures]
@@ Line 1: / Line 1: @@
 [[:techtalk:menu|{{  :techtalk:gototechnicalmenu.jpg|}}]]
 ====== EVO: Suspension - Sub-01C ======
-{{:space200x5px.jpg|}}{{:space200x5px.jpg|}}{{:space200x5px.jpg|}}{{:space050x5px.jpg|}}[[techtalk:evo:susp01|Back to 'Front Fork Info']]
+{{common:space100x5px.jpg?650|}}[[techtalk:evo:susp01|Back to 'Front Fork Info']]
 \\
@@ Line 7: / Line 8: @@
 ===== 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|
+) 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|
+) Remove the Fork Caps using a 1-3/8" Socket (or 35mm).\\
-|||
+) 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|
+) 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|
+^Actual Measurements from a 1994 Std Model Sportster Front Fork|||
-|Spring Coil Wire Diameter |  .180in|
+|Slider Tube Length (45395-92)|  24.250in|{{ :techtalk:evo:susp:forks-dampersuspparts-simpleillustration.jpg?150| }}|
-|Spring Single Rate - Gap |  .242in|
+|Slider Outside Diameter |  1.532in|:::|
-|||
+|||:::|
-|Spring Protrudes out of Slider (Fork Ext'd) |  1.375in|
+|Leg Length (45921-87 -or- 45923-87)| 16.375in|:::|
-|(no preload spacer used)||
+|Leg Asbl'd Length- To Top of Cap |  17.125in|:::|
-|||
+|||:::|
-|Damper Tube Length (45925-94)|  9.500in|
+|Spring Length (45376-94)| 21.500in|:::|
-|Damper Tube Outside Diameter |  .715in|
+|Spring Outside Diameter |  1.190in|:::|
-|Damper Tube Head OD |  1.175in|
+|Spring - Number of Coils | 53|:::|
-|Damper Tube Holes (4) Diameter |  .298in|
+|Spring Coil Wire Diameter |  .180in|:::|
-|||
+|Spring Single Rate - Gap |  .242in|:::|
-|Top Out Spring Length (45374-87)|  1.890in|
+|||:::|
-|Top Out Spring Outside Diameter |  1.20in|
+|Spring Protrudes out of Slider (Fork Ext'd) |  1.375in|:::|
-|Top Out Spring - Number of Coils | 7|
+|(no preload spacer used)||:::|
-|Top Out Spring Coil Wire Diameter |  .196in|
+|||:::|
-|Top Out Spring Single Rate - Gap |  .130in|
+|Damper Tube Length (45925-94)|  9.500in|:::|
-|||
+|Damper Tube Outside Diameter |  .715in|:::|
-| | |
+|Damper Tube Head OD |  1.175in|:::|
-|Assembled Fork||
+|Damper Tube Holes (4) Diameter |  .298in|:::|
-|Top of Damper Tube to Top of Slider (no cap) (Fork Comp'd)|  14.438in|
+|||:::|
-|||
+|Top Out Spring Length (45374-87)|  1.890in|:::|
-| | |
+|Top Out Spring Outside Diameter |  1.20in|:::|
-|  Top of Leg Cap to Top of Slider (Fork Ext'd)|  15.125in|
+|Top Out Spring - Number of Coils | 7|:::|
-|  Top of Leg Cap to Top of Slider (Fork Comp'd)|  9.563in|
+|Top Out Spring Coil Wire Diameter |  .196in|:::|
-|  Therefore -> Maximum Full Travel Equals|  5.562in|
+|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:\\
+**Pictures from a disassembled 1994 Front Fork:**\\
 {{:techtalk:evo:susp:1994-std-fork-parts-01.jpg?800|}}\\
 {{:techtalk:evo:susp:1994-std-fork-parts-02.jpg?400|}}
@@ Line 56: / Line 66: @@
 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\\
+Thanks to jaystellato for contributing to this conversation:\\
-http://xlforum.net/vbportal/forums/showthread.php?t=1971682\\
+http://xlforum.net/forums/showthread.php?t=2004931\\
+http://xlforum.net/forums/showthread.php?t=1971682\\
-\\
+All Photos are from IXL2Relax at the XLForum
+Here's the Progressive Springs Upgrade thread by IXL2Relax at the XLForum:
+http://xlforum.net/forums/showthread.php?t=2006111
+\\

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