Rear Suspension Upgrade
The running theory with suspension is that front suspension is handling and rear suspension is ride comfort. After upgrading the front forks on the Sportster Sport I realized the rear really needed to be updated. Once again I hit google and the parts books, and once again completely out of my price range. I did find that some people were swapping to touring suspension. The air ride suspension from the touring line are similar from 1997-2016. There are slight modifications as the years go on. 1997-2008 are the same, an upgraded version came out for the 2009-2013 years, and another upgraded version came with the 2014-2016 years. They come between 11 inch and 13 inch depending on model and whether it's a low or standard. I found a pair from a 2015 Road King that were 12 inches, which is a half inch shorter than what the Sportster Sports are. The owner of the Road King had recently upgraded his shocks and these were sitting around collecting dust. My assumption was that these shocks were designed to hold an 800 lbs motorcycle plus rider, passenger and gear. My Sportster Sport is only 560lbs, and I certainly weight less than 2 people and gear. Worst case scenario I hate them and have to find something else. Best case scenario is they work great. I did have to shim the shocks out for clearance and I had to buy longer bolts (use only grade 8) for the lower attachment to the swing arm. I ran the airlines between the frame (watch for pinch points) and put the air nozzle under the side cover that way it was fairly easy to get to. I made sure to to test the bike before I went out and rode it to make sure everything cleared properly (I sat on it and bounced as hard as I could). The ride was much better but I did have to put about 10 lbs of air in it. No more bottoming out going over speed bumps or pulling in to driveways. Still tight and smooth on the highway. Added bonus was if I knew I was going to hit some twisties all I had to do was add a little more air, since I now had adjustable suspension. I got the shocks for free because my buddy had upgraded his. I spent a few bucks on shims and bolts. All together I was out of pocket maybe $20.
XL1200S FRONT FORKS upgrade
I needed to upgrade my front forks on my Sportster Sport. They were worn out and I'm not exactly a small man. I dug through all the parts catalogs and looked at my options. The Sportster Sport has an unusual set up with 3 different adjusters and a cartridge system. Most of the options I cam across where out of my price range. The Dyna FXDX Superglide Sport has a very similar set up and OEM parts are still available new. While the Dyna FXDX front forks are 2 inches longer, the internal springs are only a 1/2 inch longer and will fit in the stock fork tubes of the XL1200S. They Dyna springs did fit, but it did take a little muscle. Afterwards I had to set the forks a little softer than suggested in the owners manual but they ran true and cornered amazingly. Out the door I was around$100 with springs, new seals and heavier weight performance fork oil.
2010-2019 - 48 & 72, interchangeable. stock with 3.3 gallon tank
2009-2013 - XR, interchangeable
2007-2009 - stock with 3.3 gallon tanks are interchangeable
2007-2019 - stock with 4.5 gallon tanks are interchangeable
2004-2006 - 883C, 1200C, 1200L, stock with 4.5 gallon tank are interchangeable
2004-2006 - 883, 883L, 883R, 1200R, stock with 3.3 gallon tank are interchangeable
1996-2003 - 883R, XLH, 883C, 1200C, 1200S, 883, 883 Hugger with Large 3.3 gallon tank
1996-2003 - With smaller tank fit 82-95 tanks.
1957 - 1995/1996 - XL Sportster
The 3.3 gallon tank is shorter overall.
Models with the 3.3 gallon tank have a longer seat than the models that came with the 4.5 gallon seat, to make up for the distance between the seat and the tank.
04-06 - The ECM is located under the rider. The seat pan has a pocket molded into it for clearance of the ECM.
07-09 - The ECM is still under the seat but pushed more towards the passenger area. The seat pan pocket was relocated accordingly.
10-current - The ECM is relocated near the battery compartment. The seat pan pocket is removed.
xR1200R UPSIDE DOWN FORK FLUID
The XR1200R upside down fork uses H-D Big Piston Fork Oil
REMEMBER TO CHANGE GASKETS, O RINGS AND FILTERS. CLICK ON GENERAL INFO ^ TO READ MORE ABOUT OIL
ENGINE OIL - 3qt
TRANSMISSION - 1qt
BRAKE - DOT 4 (07 AND LATER XL, 08 AND LATER XR)
DOT 5 (06 AND EARLIER XL)
FORK - TYPE E, Except for the XR1200X which uses BPF.