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Old 24th October 2020
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Default front brake conversion single piston to 4 piston

ok guys, i'm developing my winter mods list and wanted to ask about this conversion. i've got a 96 1200c with the single piston front brake. i've acquired lowers from a 2002 and a stock 4 piston caliper. i'll pick up a fork rebuild kit (any suggestions) when i'm ready to get started. is there anything i need to look out for? any problems with using the original wheel with the new lowers? will my current stock rotor work with the new caliper or do i need to buy new? this'll be my first time rebuilding the fork gaskets so is there anything i need to be aware of there? thanks for your help.


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Old 24th October 2020
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Hey Rick. Did you also pick up an 11/16” front master cylinder to go with the dual disc/calipers?


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Old 24th October 2020
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going to stay with single disk brake but upgraded 4 pot caliper from a 2002 sporty. i believe my current mc is 9/16 so i "think" that may not need to be changed.
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Old 24th October 2020
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Ahh ok. I thought you were going to dual disc/caliper. Single caliper should still be 9/16”.


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Old 25th October 2020
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Default

Here's the Sportsterpedia section on the front forks:
http://sportsterpedia.com/doku.php/techtalk:evo:susp01

It has info and pics (in a sub page) from my 1994 fork rebuild.
http://sportsterpedia.com/doku.php/techtalk:evo:susp01c

A link to my thread about installing Progressive springs:
http://xlforum.net/forums/showthread.php?t=2006111

A thread regarding various Damper Tubes & other fork parts:
http://xlforum.net/forums/showthread.php?t=2004931

The following tips 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 (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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Last edited by IXL2Relax; 25th October 2020 at 05:51..
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Old 27th October 2020
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thanks ken. i'll check the links. appreciate it.
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