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====== EVO: Suspension - Sub-01C ======
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===== 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.

The following tips from the XLF threads were especially helpful:\\
1) Loosen (not remove) the Damper Bolts (6mm Allen Key) while the forks are still on the bike & under spring tension\\
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)\\\
.... where the threads begin to engage - This tip was extremely helpful in getting the cap back on while compressing the spring.\\
4) Use a 1-1/2" PVC coupling for the fork seal driver (coupling center spline removed)\\
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^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|:::|
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**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|}}
{{:techtalk:evo:susp:1994-std-fork-parts-03.jpg?400|}}\\
{{:techtalk:evo:susp:1994-std-fork-parts-04.jpg?400|}}
{{:techtalk:evo:susp:1994-std-fork-parts-05.jpg?400|}}\\


Reference Additional Information on the 1986-2003 models in these XLForum Threads:\\
Thanks to jaystellato for contributing to this conversation:\\
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\\
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

Here's the Progressive Springs Upgrade thread by IXL2Relax at the XLForum:
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

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