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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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  #1  
Old 3rd August 2021
Nicktater's Avatar
Nicktater Nicktater is offline
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Sportster/Buell Model: XL1200C
Sportster/Buell Year: 2006
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Default Fork issues after rebuild.

Two bikes:
02 XL883R (wife’s)
06 XL1200C (mine)

Fork rebuild needed.

02 XL883R
Fork oil unknown, came with bike.
Progressive 2” lowering kit. Originally didn’t put in the 2-1” damper springs or change oil. With the rebuild I put them in.
Damper rod 45925-97, 9” per sportsterpedia
Original tubes, 30* angle
Now using Redline 10wt suspension fluid, 10.8 oz (per official Harley manual)
1” preload
She weighs maybe 100 pounds

06 XL1200C
Fork oil Type E, changed couple years ago.
Progressive fork springs
Damper rod 45925-04, 9” per sportsterpedia
8” over tubes, 48* angle
Now using Redline 10wt suspension fluid, 11.6 oz (per official Harley manual)
1” preload.
I weigh 200 pounds

I didn’t think to measure and compare damper tubes until now cause the ride results are different. I rebuilt them separately so all parts did not get mixed. Went with Redline 10wt cause all the graphs and charts showed it being very similar to Type E, but not as extreme a viscosity change in temp.

So, slight differences in hers vs mine.
Mine are just right, maybe a little stiff.
Hers are SOFT. So soft that they just keep moving up and down and don’t seem to ever want to stop. Did not have this issue before the rebuild on hers.

Hers doesn’t bottom out, but really spongy.
I don’t know the full suspension travel of mine but from sitting no rider the compression at most was 1.75” during the ride. We just rode together first time since I rebuilt them so same road traveled. Different reactions. She told me when we got back and if I hold the front brake and pump the forks, there is a BIG difference.

So my questions:
Do I need to add more oil?
Do I need heavier or lighter oil?
Should I rebuild again and swap the rods? What are the differences in these rods?
Did adding the extra 2” to damper springs cause this?
Do I not have enough preload?
Is it something else?
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  #2  
Old 3rd August 2021
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wtwolf wtwolf is offline
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i would try heavier oil and measure what you put in.
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  #3  
Old 4th August 2021
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Depending on how hot the summer will be.

I use 20wt or 30wt in mine. I am a big guy when it comes to suspension.
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  #4  
Old 4th August 2021
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Nicktater Nicktater is offline
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Sportster/Buell Model: XL1200C
Sportster/Buell Year: 2006
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Default

Thanks, just what I was thinking but wanted to ask the more knowledgeable first. IÂ’m gonna try 20 first and go to 30 if not enough.

I checked full travel after work yesterday, both only travel 4” total. With 2-1” lowering spring spacers on her damper tubes, and just the stock damper springs on mine, I’m wondering if the progressive springs limit compression now. Oh well. Just something I never worried about. Just need to stiffen hers up a bit.

Thanks
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