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  #1  
Old 19th May 2019
Paintbullits's Avatar
Paintbullits Paintbullits is offline
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Join Date: Apr 2019
Posts: 3
Sportster/Buell Model: xlch
Sportster/Buell Year: 1972
Sportster/Buell Model #2: XL Hugger 1250
Sportster/Buell Year #2: 1998
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Default someone school me on suspension please?

So the plan is eventually to turn my 98 hugger that i took back from being a "bobber" into a somewhat off road capable machine, while not being horrible on road and still looking tough.

That means;
  • mid controls
  • spoke wheels
  • more aggressive tires
  • scrambler bars
  • chain conversion
  • higher exhaust
  • and of course taller suspension.


I also have some other unrelated things planned such as;
  • cleaning up the controls
  • integrating blinkers into a set of hand guards
  • ammo tin saddlebags
  • ez clutch ramp
  • a complete rewire is eventually necessary (hoping to make it internal in the backbone)
  • better brakes
  • led sled kicker kit

Other maybe someday upgrades include a baker 6 speed depending on what happens when i play around with the sprockets, & a Buell lighter crank.

But enough of that, it was mostly me finally typing out my thoughts. The main question I have for you all is about suspension upgrades. The rear shocks max length is 15" before I need to fab up something to keep the chain off the swing-arm correct?

Now on to the front, oh boy. From my reading on the internet ive found a few things are possible, such as using a full ktm front end (i dont want to do bc i would rather keep the stock triples), or honda xl600r forks (would need to do a bit of fab work to fit the hd rim). But im starting to think about just beefing up the stock front end. I cant find it now but someone mentioned that the hugger suspension I have uses the same stanchions as the other models, the height is just a function of the internals, whats more some internals offer more suspension travel (1200s I believe?). Is this true? I cant seem to find much about it.

I need to head out tomorrow and take some measurements off the bike and see what i can find out but I think the stock length of the shocks is 11" and the forks are something like 30" or 31". My thinking is if i basically go with a +4 font end to match the 4 inch higher rear end (11"to 15") I should be in pretty decent shape. But all the converting metric to imperial involved along with all the different measurements is confusing me. Is it even possible to do what im thinking here?

I would love to hear any other thoughts, concerns, or questions you have on the rest of my plan.
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  #2  
Old 19th May 2019
IXL2Relax's Avatar
IXL2Relax IXL2Relax is offline
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Posts: 6,666
Sportster/Buell Model: Sportster 883►1200
Sportster/Buell Year: 1994
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Here's the Sportsterpedia EVO section on Front Forks:
http://sportsterpedia.com/doku.php/techtalk:evo:susp01

And some pages in the REF section:
http://sportsterpedia.com/doku.php/techtalk:ref:susp06
http://sportsterpedia.com/doku.php/techtalk:ref:susp07
http://sportsterpedia.com/doku.php/techtalk:ref:susp04


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  #3  
Old 19th May 2019
Paintbullits's Avatar
Paintbullits Paintbullits is offline
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Join Date: Apr 2019
Posts: 3
Sportster/Buell Model: xlch
Sportster/Buell Year: 1972
Sportster/Buell Model #2: XL Hugger 1250
Sportster/Buell Year #2: 1998
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So from reading that chart it does seem like my fork tubes could do with some extra length just by switching out damper rods (45938-92 with 45925-94). Another useful piece of info from this its i now know how long a set of tubes i have (24.25) so that i could in theory get a 4" longer set and make up a 4 inch spacer for the top cap.

Only real question left is if i can actually get a damper tube that will give me more travel. Plenty online claim that (along with adjustable damping and other fancy bits), but none advertise for what length or even what bikes they fit.

Other questions also include if im an idot i suppose along with any blatenty obvious problems with my plan im not seeing.
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  #4  
Old 8th June 2019
Whylee Whylee is offline
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Posts: 16
Sportster/Buell Model: Xl1200N
Sportster/Buell Year: 2018
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I used the 11 1/2 inch extended damper tube kit from Traker Die. It wll give you either 2 or 4 inchs more travel, depending if you use the optional 2 inch spacers. Using this kit I noe have just over 7 inchs of travel.
I used the 15 inch burley stilletto shocks, far from the best, but they work for now.
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  #5  
Old 9th July 2019
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vagrant318 vagrant318 is offline
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Location: Madison
Posts: 180
Sportster/Buell Model: 1200S
Sportster/Buell Year: 2000
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My bike started as a 1200S, if you want to do more serious off road you'll want something better imho.
Otherwise look at hugo moto, they use stock front ends
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