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Discussion Starter · #1 · (Edited)
Hello All,

As I progress to turn my '09 into a streetable version of the AMA Series racebike, I have a few remaining components to change over, and one on my mind has been the Forks. Rear is all set thanks to Jeremy Connors, and is sale of the Ohlins +2". To match the rears I wanted to go with Ohlins Cartridges, and with many e-mail conversations to Mike at Ohlins USA, they were set to make me a set of fully adjustables for my forks. Finaly this morning aI received an email:

"Sorry I was working on trying to find solution but it appears the parts we needed from Sweden are truly no longer available. While we have the kit that is only part of the equation and now we don’t have the ability to make the “missing” parts."

After I finished throwing a temper-tantrum, and drying the tears from my eyes, I replied with what they would recommend for options to match the Ohlins Rears. I am awaiting Mike's reply.

I went the cheap route when my forks were noticeable leaking after I brought it home from the seller, so I had the Race Tech Gold Valves installed with the rebuild. Never rode the bike with stock fork internals, and wasn't too keen on jumping in with the big $$ for the full cartridges from Race Tech. Now I kind of regret it.

So my search for fully adjustable cartridges begins again. Options I have found searching this morning are:

X-Model H-D Forks
Performance Suspension Kit | Harley-Davidson USA

Race Tech
RT - Digital Product Search (racetech.com)

Traxxion
AK-20 Axxion Cartridge Kit (AK20HD-XR1200-1) - Traxxion Dynamics

K-Tech X
(X Model Only)
Front Fork Cartridges 25IDS Harley Davidson XR1200X 2011> Showa K-Tech (ktechsuspension.com)

Andriani Misano
Andreani Misano Cartridge Kit H.D. XR 1200 2008- (teknikmotorsport.com)

Legends
(no plans to go this route)
Legend AXEO39TS Front End Suspension (Requires Separate Purchase of +2 Fork Tubes) – Legend Suspensions

GP Suspensions
www.gpsuspension.com


Knowing the 09-10 XR1200 and the 10-12 XR1200X Forks are not the same, some of the companies listed above only have full carthridges for the X Models. I would have to purchas a set of X Forks then send them out... I have read where some companies require me to send in my forks to have the kits installed as well. I do not mind doing that either.

I really wanted to go with Ohlins, as will await Mike's reply on what he would recommend. In the eantime, let me know what you think about what cartridges you have pros and cons would be appreciated.

Thank you in advance.
 

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How about this option? Öhlins FF 520 and Andreani mounting plate kit.

Öhlins ff 520

Andreani
 

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Discussion Starter · #4 ·
Thanks @Hoodee for the information. $3200.00(before tax and before shipping) is way over my budget for a replacement front end.

Since starting this topic, I am still reading and searching this place for it's history of knowledge. Using "Cartridges" as a search I still have a lot more to read. Some cartridges and a lot of links to places back then are no longer available. Trying NOT to have to buy a set of X-Forks to have upgrades made to them. Suspension is not my best, so I'd leave it up to companies to ask me the questions, and build based off my answers.
 

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I had a set of cartridges put in by GP Suspension and am very happy with the results. The forks were done a few hundred miles before adding Ohlins shocks, so I had time to feel them out independently.

It was $ well spent. The forks lost their tendency to pogo with any throttle adjustments. They also don’t dive abruptly when on the brakes. They finally feel like they are doing their job.

I recently rode the XR on the kart track at Sears Point and didn’t have any complaints with the suspension. I regularly hustle the bike around on HWY9 too, and have been able to surprise a few sportbike riders with the ability to hang with them.

The minor issue I have it that once installed (with stock handlebars, you can’t access the damping adjustment screws on the top of the forks. FYI: one fork leg handles compression, the other does rebound.

I can’t give you an accurate cost estimate though. I got a ‘friends and family’ discount since I’m close to the owner. The place is owned by the AFM president, Berto.
 

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Discussion Starter · #7 · (Edited)
Thanks @Enchanter

Here is the link to the XR1200 Cartridge kit.

Automotive lighting Telephone Telephony Corded phone Automotive design




I wound like both compression and rebound adjustability in both forks.
 

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It that possible with the stock fork lowers? I don’t think that I’ve ever seen compression and rebound on the top of the same fork on any motorcycle.

Not saying I know for sure…just can’t recall.

EDIT: Just googled it…yup, some fork caps have both…
 

· Sonya's a pretty kitty!
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Hi Corey,
Possibly worth my mentioning here that many years ago I dreamed up and fabbed an air cap kit for my 2010 non X. I wrote up the mod and posted it in these pages under my name so I'm sure it's still here if that gives you any worthwhile background reading. I still run the air caps at ~ 8 - 10 psi and like the end result for a balance of urban and country road use, along with around 330 ml of 15W fork oil in each leg. It took a little experimentation to settle on that combo for my 85 kg weight and taste in ride quality, but on the whole it works for me and is spectacularly less expensive than any cartrige kit or, heaven forbid, replacement forks. I seem to remember it costing me around $150 AUD all up. Anyhow good luck with your suspension quest.

J.
 

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Discussion Starter · #10 · (Edited)
Thanks Shackman for the information, but I am still looking to go with cartridges, eventhough it might be a little less than buying the whole suspension kit from H-D, then selling off the rear shocks.

"Fits '08-'13 XR1200™ models. Stock on International '10-'13 XR1200X™ models."

Performance Suspension Kit | Harley-Davidson USA

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Sorry, I don't mean to hijack your thread, but, I just wish Howard, our resident Ohlins suspension Guru was still alive (he passed a couple of years back), his forum name was FastHarley, and he had his own shop in Florida (look up some of his posts, they may prove helpful in some way. And he helped many forum members with their suspension issues, he even knew what to do with the original XR1200 forks (pre X models) to get them to perform properly.

I opted to buy a used set of X model BPF forks from a forum member and send them to David Beherens at Fast Bike Industries in North Carolina. I had already purchased the Andreani piston kit part# 409/HD1, and sent that to him as well, he also installed the Ohlins spring kit part# 4744-90 with custom preload spacers, and topped everything up (to the proper level) with Ohlins fork fluid. at that time, I opted to not go with the Ohlins Cartridges, frankly, because i didn't want to spend the money, as I recall, it was pretty expensive.

I got everything back from FBI in about 3 weeks, and I was into it just slightly over $1,000 with shipping and insurance.
add to that the $1100 i spent on a used set of Ohlins 852 rear shocks that I got from a different forum member, and for about $2100 total that I spent, it really transformed the entire feeling of riding the bike, now it was sure footed and stayed planted where I pointed it, no matter how rough the terrain was, in my opinion, the best money I ever spent on the bike.

David had his own XR1200 that was set up for racing, I've seen that video on you tube some time ago, it might be worth speaking with him to see what he suggests.his number is (828) 243-7240 or [email protected]

Good luck with your project, and I look forward to following along.
Regards
Roy
 

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Discussion Starter · #12 ·
You can chime in on any of my threads at any time Roy, and I appreciate the information as that is on my list of possibilities.
 

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Hello All,

As I progress to turn my '09 into a streetable version of the AMA Series racebike, I have a few remaining components to change over, and one on my mind has been the Forks. Rear is all set thanks to Jeremy Connors, and is sale of the Ohlins +2". To match the rears I wanted to go with Ohlins Cartridges, and with many e-mail conversations to Mike at Ohlins USA, they were set to make me a set of fully adjustables for my forks. Finaly this morning aI received an email:

"Sorry I was working on trying to find solution but it appears the parts we needed from Sweden are truly no longer available. While we have the kit that is only part of the equation and now we don’t have the ability to make the “missing” parts."

After I finished throwing a temper-tantrum, and drying the tears from my eyes, I replied with what they would recommend for options to match the Ohlins Rears. I am awaiting Mike's reply.

I went the cheap route when my forks were noticeable leaking after I brought it home from the seller, so I had the Race Tech Gold Valves installed with the rebuild. Never rode the bike with stock fork internals, and wasn't too keen on jumping in with the big $$ for the full cartridges from Race Tech. Now I kind of regret it.

So my search for fully adjustable cartridges begins again. Options I have found searching this morning are:

X-Model H-D Forks
Performance Suspension Kit | Harley-Davidson USA

Race Tech
RT - Digital Product Search (racetech.com)

Traxxion
AK-20 Axxion Cartridge Kit (AK20HD-XR1200-1) - Traxxion Dynamics

K-Tech X
(X Model Only)
Front Fork Cartridges 25IDS Harley Davidson XR1200X 2011> Showa K-Tech (ktechsuspension.com)

Andriani Misano
Andreani Misano Cartridge Kit H.D. XR 1200 2008- (teknikmotorsport.com)

Legends
(no plans to go this route)
Legend AXEO39TS Front End Suspension (Requires Separate Purchase of +2 Fork Tubes) – Legend Suspensions

GP Suspensions
www.gpsuspension.com


Knowing the 09-10 XR1200 and the 10-12 XR1200X Forks are not the same, some of the companies listed above only have full carthridges for the X Models. I would have to purchas a set of X Forks then send them out... I have read where some companies require me to send in my forks to have the kits installed as well. I do not mind doing that either.

I really wanted to go with Ohlins, as will await Mike's reply on what he would recommend. In the eantime, let me know what you think about what cartridges you have pros and cons would be appreciated.

Thank you in advance.
Which part number springs did you go for in the ohlins rear shocks?
 

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I'm happy with the Showa BPFs and Andreani/Ohlins upgrade. I did my own install. It isn't that hard if you have the tools. And since I bought the valves through Fast Bike, Dave gave me some tech advice.

Cartridges are great! But the upgraded BPFs are perfect for mere mortals.
 

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2,082 Posts
Discussion Starter · #15 ·
Which part number springs did you go for in the ohlins rear shocks?
The springs were on the used rear Ohlins when I bought them from a Member here.
Ohlins 85 STX 36 Twin Trophy Version S36PR1C1L 376mm +10/-0mm 101 Stroke
"[16”, or +2” over]" Springs 06380-04/21/30
 
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Discussion Starter · #16 ·
Still researching and reading on out the options in cartridges, and there are a lot of options to suit ones taste, weight, and riding style when it comes to suspension.
 

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Discussion Starter · #17 ·
Mike from Ohlins replied to my last e-mail with the following, after he stated they could not replicate the XR Series Race Cartridges:

"Corey, I have asked one of my dealers (who also works with us on our Moto America Trailer) if he can do this job for you. He has machining ability at his shop, and so we are sending him the information and will put you in touch with him. This way maybe you can have the matched Öhlins."

Not getting my hopes up, but would like to keep the XR all Ohlins if possible.
 

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I wonder if that's something to do with the fork legs being Showa? A small run of parts just to satisfy the racing.

I feel very fortunate to have the factory Ohlins fitted, Its also handy having an official dealer with full tech support just down the road. When I had mine serviced in 2020 I never thought to ask what was inside and maybe get some pics and part numbers.

Good luck with getting sorted, I hope they can help, you could just put some Ohlins stickers on and pretend :unsure: That was a joke I know how dedicated you are to the cause ;)
 

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Discussion Starter · #19 ·
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