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EVO: Suspension - Sub-01C
1994 XLH Front Forks Disassembled - Measurements w/Pictures
The following information was collected when the stock 1994 Front Forks were disassembled to be cleaned
and the internal springs were replaced with a set of Progressive-brand progressively wound springs.
The following tips from the XLF threads 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 (or 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)
Pictures from a disassembled 1994 Front Fork:
Reference Additional Information on the 1986-2003 models in these XLForum Threads:
Thanks to jaystellato for contributing to this conversation:
http://xlforum.net/forums/showthread.php?t=2004931
http://xlforum.net/forums/showthread.php?t=1971682
All Photos are from IXL2Relax at the XLForum
Here's the Progressive Springs Upgrade thread by IXL2Relax at the XLForum: http://xlforum.net/forums/showthread.php?t=2006111