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Sportster Motorcycle Suspension, Frame, Forks, Handlebars, Fuel Tank, Oil Tank, Fenders Discuss Sportster Motorcycle Suspension, Frame, Forks, Handlebars, Fuel Tank, Oil Tank, Fenders problems, advice, and/or how tos.

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  #41  
Old 7th July 2019
Bluto Bluto is offline
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Sportster/Buell Model: XL1200R
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Finally got the SE fully adjustable fork kit installed, was a Royal PITA thanks to the oversized washers HD supplied. (item 20 above) They were 32.5 mm OD, fork tube ID is 31mm so I machined the washers down to 30.5 mm then it all went together OK the second time.
Did a short test ride, a definite improvement and maybe will be even better with some fine tuning...all settings are per HD's recommendations currently
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  #42  
Old 7th July 2019
shanneba shanneba is offline
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Did you use HD Type E fork oil?

When I had my forks installed the dealer had to order 2 of part number 48738-07 Spring washer.

In the instructions for the SE Fork kit that part number is listed as the fork spring.

In the 2013 Sportster parts manual 48738-07 is listed as
WASHER (2) XL1200C, XL1200C ANV, XL1200CA, XL1200CB, XL1200CP, XL1200V, XL883R

Now I know why they had to order the parts
I assume they used the 2 original washers from my stock forks and the 2 they ordered.
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2013 XL1200C

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  #43  
Old 8th July 2019
Bluto Bluto is offline
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I did use HD Type E fork oil, looks suspiciously like ATF ;-) Thanks much for the PN, those washers are not used on my 08 XL1200R so I didn't even have two of them...but will pass that on to New Castle HD (who sold me the kit) and hopefully they will let HD know, maybe they would have a contact there that can correct the problem.
Rode another hundred miles today, forks are much improved and the kit is worth the trouble and $$$.
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  #44  
Old 8th July 2019
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Toejam503 Toejam503 is offline
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I just did a fork oil change and thought Type E sure looks like ATF,too.
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  #45  
Old 27th July 2019
Bluto Bluto is offline
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A photo showing the improvised special tools I used for kit installation.
The damper extension tool is actually a 10mm x 1.0 bicycle rear axle w/ cone nut, worked fine. Locally no one carried hardware in this size, eventually I realized I'd seen that thread somewhere before.
Used two Ohlins shock wrenches connected to two ratcheting tie down straps to compress the spring, a bit dicey but did the job.
The Jawhorse was quite handy as usual, highly recommended, use mine for all sorts of stuff.

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