Table of Contents

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EVO: Suspension


Front Fork Info

Sub-Documents

* . . . Future Subject

* . . . 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


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 Tube45381-8723.37545395-9224.25
Damper Tube45925-8810.87545938-927.5
Spring-#Coils45376-8720.2545372-9221.5_47c
1993
Slider Tube45381-8723.37545395-9224.25
Mid-yearSlider Tube45395-9224.25 ● ●
Damper Tube45925-8810.87545938-927.5
Spring-#Coils45376-8720.2545372-9221.5_47c
1994-1995
Slider Tube45395-9224.2545395-9224.25
Damper Tube45925-949.5045938-927.5
Spring-#Coils45376-9421.5_53c45372-9221.5_47c
1996Models »StdLengthHug&CtmLength
Slider Tube45395-9224.2545395-9224.25
Damper Tube45925-949.50 45938-927.5
Spring-#Coils45376-9421.5_53c45372-9221.5_47c
1997-1998
Slider Tube45395-9723.375 45395-9224.25
Damper Tube45925-979.045938-927.5
Spring-#Coils45376-97 45372-9221.5_47c
1999-2003Models »Std&CtmLengthHuggerLength
Slider Tube45395-9723.37545395-9224.25
Damper Tube45925-979.045938-927.5
Spring-#Coils45376-97 45372-9221.5_47c

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 Damper Tube Forks Notes
Slider TubeDamper TubeSpring
2004-2008 04-08 883/C 1200C/R
05-08 883R
07 XL50
08 1200L 		45395-0445925-0445376-04
2005-2006 883L 46218-0545938-9246267-05
2007 883L 46218-0547313-0747299-07DT#47313-07 believed to be 6.5“
2007-2012 883N34) 1200N35) 46218-0547313-0747299-07
2008 883L 45395-0447313-0747299-07
2009-2010 883/C/L/R 1200C/L/R 45395-0945925-0945376-09
2011 883L/R 1200C/CP/L/X 46218-0545938-9246267-05
2012 ?
?

Cartridge Damper Forks

Models Outer TubeLeft Cart/RodSpringRight RodSpring Notes
2008-2009 XR1200 46884-0846878-0846882-0846359-0646882-08Lt uses Cart. Rt uses Rod + Spring
2010 XR1200 10628 46681-101041846681-101041846681-10 is Compl. Rod Assy (each side)
2011-2013 XR1200X 10628 46681-101041846681-101041846681-10 is Compl. Rod Assy (each side)
?

Slider Lower Legs

Model(s)Lower Sliders
Left Leg		Lower Sliders
Right Leg		 Rt Brk
Mount
2004 36)883/883C/1200C45921-0045923-00 ?
2004-200737) 38)39)40)1200R45921-0045922-00
2005-200641)42)883/883L
883C/1200C		45921-0045923-00 ?
2005-200743)44)45)883R46450-0546449-05 ?
2007 46)All except 883R
1200R/1200N		45921-0045923-00 ?
200747)1200N48726-0748716-07 ?
2008 48)All except 883R
1200R/1200N		46075-0446076-04 ?
2008-2013 49)50)51)52)53)54)883R46450-0846449-08 ?
2008-2009 55)56)1200R46075-0445922-08 ?
2008-2012 57)58)59)60)61)1200N48726-0848716-08 ?
2008-201062)63)XR120046880-0846879-08 ?
2009 64)883/883C/883L
1200C/1200L		46075-0446076-04 ?
2009-2014 65)66)67)68)69) 70)883N48726-0848716-08 ?
2010 71)883C/883L
1200C/1200L		46075-0446076-04 ?
2010-2015 72)73)74)75) 76) 77)XL1200X48850-1048849-10 ?
2010-2014 78) 79)80)81) 82)XR1200X48786-1048785-10 ?
2011 83)1200L46075-0446076-04 ?
2011-2016 84)85) 86) 87) 88)89)883L49401-1149403-11 ?
2012 90)1200C/1200CP49411-1149412-11 ?
2013 91)1200V46075-0446076-04 ?
2013 92)1200C/1200C Anv
1200CP/1200CA/1200CB		49411-1149412-11 ?
2014-2016 93) 94) 95)1200V4550005645500075 ?
2014-2015 96) 97)883R4550005545500076 ?
2014-2016 98) 99) 100)1200C/1200CP
1200CA/1200CB		49411-1149412-11 ?
2015-2016 101) 102)883N4550005445500057 ?
2015-2016 103) 104)1200T49401-1149403-11 ?
2016 105)XL1200X4550028745500290 ?

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


Fork Oil Drain Screws

45790-80 - Stock Drain Screw with Washer (Req 2 for 2 forks)
(Starting in 2008, some models do not have fork oil drain screws)

45815-03 - Chrome Fork Slider Drain Screw Kit106)
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)
2009-2012
35)
2007-2012
36) , 37)
2004 HD Sportster Parts Catalog pg 67
38) , 41) , 43)
2005 HD Sportster Parts Catalog pg 71
39) , 42) , 44)
2006 HD Sportster Parts Catalog pg 71
40) , 45) , 46) , 47)
2007 HD Sportster Parts Catalog pg 71
48) , 49) , 55) , 57)
2008 HD Sportster Parts Catalog pg 71
50) , 56) , 58) , 64) , 65)
2009 HD Sportster Parts Catalog pg 109
51) , 71) , 72)
2010 HD Sportster Parts Catalog pg 103
52) , 73) , 83) , 84)
2011 HD Sportster Parts Catalog pg 103
53) , 74) , 85) , 90)
2012 HD Sportster Parts Catalog pg 103
54) , 75) , 81) , 86) , 91) , 92)
2013 HD Sportster Parts Catalog pg 115
59) , 66)
2010 HD Sportster Parts Catalog pg 105
60) , 67)
2011 HD Sportster Parts Catalog pg 105
61) , 68)
2012 HD Sportster Parts Catalog pg 105
62)
2009 HD Sportster Parts Catalog pg 111
63)
2010 HD Sportster Parts Catalog pg 107
69)
2013 HD Sportster Parts Catalog pg 117
70) , 76) , 82) , 87) , 93) , 96) , 98)
2014 HD Sportster Parts Catalog pg 81
77) , 88) , 94) , 97) , 99) , 100) , 103)
2015 HD Sportster Parts Catalog pg 81
78)
2010 HD Sportster Parts Catalog pg 109
79)
2011 HD Sportster Parts Catalog pg 107
80)
2012 HD Sportster Parts Catalog pg 107
89) , 95) , 104)
2016 HD Sportster Parts Catalog pg 81
101)
2015 HD Sportster Parts Catalog pg 83
102)
2016 HD Sportster Parts Catalog pg 87
105)
2016 HD Sportster Parts Catalog pg 85
106)
Folkie - xlforum.net/vbportal/forums/showthread.php?t=738626
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Trace: • EVO: Suspension