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Fork Cartridge Kits and Forks

5147 Views 86 Replies 15 Participants Last post by  amarzano, 
CoreyDSFA
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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CoreyDSFA
2
Thanks @Shackman for the advice. I bought the steering damper kit from a member here a ways back. Installed it from the instructions, and did notice the fork bracket pivot bolt seems a little on the short side. Haven’t had any issues with it as it is, but will look into a longer bolt. Sure, add that info here for those that might want to add a steering damper.

As for Fast From The Past, I know Jim well, as I bought my Tarrozi Rearsets and Fork Brace from him when I raced my GPz550 in AFM 2010-2013. His sticker was on my race bikes all those years. Sent him a framed championship poster after winning Foumula Vintage. Nice guy!

Sky Wheel Tire Vehicle Motorcycle



Tire Wheel Vehicle Helmet Automotive tire
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ytman
🍻🍻
Here’s to a speedy turn around quality work!
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CoreyDSFA
I will admit, I am no Suspension Guru, but here is my 4.5” of fork travel I am getting, as they came off the bike. Does this mean anything? Too much? Too little?

Temperature Tool Measuring instrument Font Tape measure
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S
CoreyDSFA said:
Thanks @Shackman for the advice. I bought the voltmeter kit from a member here acways back. Installed it from the instructions, and did notice the fork bracket pivot bolt seems a little on the short side. Haven’t had any issues with it as it is, but will look into a longer bolt. Sure, add that info here for those that might want to add a steering damper.
Click to expand...
OK, here it is. The NHK damper which I found at FFTP whose specs best fit the XR was model ODM3000E. The damper has a standard body diameter of 25 mm, a stroke of 195 mm and a total length of 395 mm. In April of 2020 it cost me $165 USD and $64 USD to ship to Australia. The NHK kit includes a nifty 2 bolt damper body clamp but members wanting to fit one to an XR need to source their own fork leg and frame down tube clamps. However both are readily available on eBay. The stroke length is critical; XR's aren't blessed from the factory with excessive steering lock (as I found out on my very first test ride from the dealer on mine, when I almost put it into the gutter trying to do a wheels up U turn in an average suburban street) and you need all of that 195 mm and some playing with clamp positions to retain all your existing lock to lock.
German/European members might be interested to know FFTP ship the damper with copies of TUV certification.

Trust all this helps.

J.
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CoreyDSFA
Forks shipped. Now the waiting begins. I feel like a parent sending a child off to camp for a few weeks, but I don't have any kids that I know of.

Updates as I get them.
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CoreyDSFA
Not much to report yet, but received this text yesterday:


Hello Corey,

Your repair order for your XR 1200 is tentatively scheduled to start 01/26/2023, you will receive another message when we have an update.

Thanks,
KFG MOTORSPORTS
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CoreyDSFA
Fork caps are being made. They will be making a “run” of them for the future customers that want the same set-up as I am having done. No ETA as of yet, and no pricing has been determined.
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CoreyDSFA
Forks are still in a holding pattern, as KFG has reached out to another company they thought could have a set of the caps needed to make these Ohlins Cartridges work. A few days ago KFG replied that this other company "Has zero caps available".

KFG will need to make the tooling to make the "run" of caps. This will determine if it is affordable to make them of not. To reiterate, the BPF Forks from the X Models would be easier to install these cartridges. I have other options, but it will come at an price of buying a set of X Forks, then sending them to KFG. Still no idea what the charges would be for either the Non-X, or X Ohlins Cartridge install. I have only paid for shipping to get my forks to KFG, as my XR sits on the battery tender, strapped to the service lift.
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CoreyDSFA
For information, the 2009-2010 Non-BPF Left Fork Complete is no longer available from H-D, but the right side is available. As of this posting The Vintage Site shows 5 left side complete are remaining.

www.vpartsinc.com

46886-08

OEM: HARLEY-DAVIDSON Description: FORK ASY LH/FRT/BLACK Weight: 13.4 LB
www.vpartsinc.com www.vpartsinc.com
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CoreyDSFA
Well no good news or bad news yet. KFG is looking for other well-known Ohlins Shops to see if they have the caps needed. If they are found, this will be easily replicated. If not, starting from scratch might not be affordable. The BPF Caps are redily available, and this route will be my only choice to get Ohlins Cartridges on my bike.

Plan B: I would sell the current and freshly rebuilt 2009 Forks with Race Tech Gold Valves installed, set up for a 210 lbs rider, if I have to go down this path. KFG will be rebuilding them if this path is taken.

More news as it comes in...
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CoreyDSFA
Well not the good news I was hoping for. KFG can make the caps, but it will take a few months. In the meantime they will rebuild my forks and send them back to me. Only one fork cap is needed to make the caps used with this kit. I will send them one to have for this.

1. Wait till the caps have been made, then send my forks to them again once the caps are ready, and have the cartridges installed.

OR

2. Buy a set of BPF Forks, send them to have the cartridges installed, and sent back to me. The caps for the BPF Forks are readily available. I will then list my current forks for sale afterwards.
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CoreyDSFA
Once KFG has the cap I send them, it will be about 2 month before they are ready to install the Ohlins Cartridges in the 09-10 Non-BPF forks for anyone looking to do this.
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Chipmaker
That sounds like wayyyy too much trouble Corey. After seeing what you are going thru, I doubt anyone will go that route. Are you planning on racing your XR? If not, get a set of BPF's and go ride.
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CT XR rider
If you’re thinking of getting the BPF’s, don’t buy them separately, you could buy the premium suspension kit for around $1200 and sell the rear shocks on here for about $450, total outlay for the BPF forks will be around $750. That’s what I did
Regards
Roy
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geno
Here's what happened to the rear shocks from the premium suspension kit I purchased:
Automotive tire Automotive lighting Motor vehicle Automotive design Toy


Just kidding, I think I sold them for $250. I did keep the forks and those were rebuilt by Race Tech.

At the time of the photo above, our most esteemed member magoo stated that:

I believe the proper procedure for disposing of those things involves a lead container enclosed in several feet of concrete. They have a half life of 1,000 years......Hundreds of years from now, when those shocks are recovered by 25th century archaeologists, they will look upon them in awe and say, "Can you believe they rode on this shit?"
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CoreyDSFA
@Chipmaker
No plans to race, just would like Ohlins front and rear. It is a preference.

@CT XR rider
The front and rear kit 54530-10 sells for $1625.00 before tax and there is someone on e bay listing a set of USED rears, same from that kit and on X-Models, for $616.00 before tax.

www.ebay.com

2009-2013 Harley Davidson Sportster XR1200 Red Rear Shock Absorbers w/ Reservoir | eBay

Find many great new & used options and get the best deals for 2009-2013 Harley Davidson Sportster XR1200 Red Rear Shock Absorbers w/ Reservoir at the best online prices at eBay! Free shipping for many products!
www.ebay.com

Product Office supplies Font Line Liquid


Seems to be the way to go CT in purchasing the kit and selling off the rears. I have read this option many times on this place. I’d just have to see if the kit is on backorder or not. I do know the fronts are readily available.

I’ll know more tomorrow.
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CoreyDSFA
geno said:
Here's what happened to the rear shocks from the premium suspension kit I purchased:
View attachment 254519

Just kidding, I think I sold them for $250. I did keep the forks and those were rebuilt by Race Tech.

At the time of the photo above, our most esteemed member magoo stated that:

I believe the proper procedure for disposing of those things involves a lead container enclosed in several feet of concrete. They have a half life of 1,000 years......Hundreds of years from now, when those shocks are recovered by 25th century archaeologists, they will look upon them in awe and say, "Can you believe they rode on this shit?"
Click to expand...
Now that is funny Geno!
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CT XR rider
wow..I guess inflation even affected the Motor Company...back just a few years ago the suspension upgrade kit #54530-10 listed for $1500.00, and most part guys could discount them 20% for a out the door price of $1200, I think I sold the brand new rear shocks for $425 plus the ride. that's how it worked for me.
Regards
Roy
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ytman
Chipmaker said:
That sounds like wayyyy too much trouble Corey. After seeing what you are going thru, I doubt anyone will go that route. Are you planning on racing your XR? If not, get a set of BPF's and go ride.
Click to expand...
If Corey were to get this shop the cap that they need and they did their magic, no one else would have to go that route. Anyone could ship KFG their early forks and have Ohlins cartridges installed. That would be a noble thing to do. I, on the other hand am far more selfish. I like the X forks for their longer upper tubes and shorter lowers. I don’t know if they would perform differently with equal internals but I bet the early forks with the Gold Valves and good springs would out perform stock BPFs. Other companies install their cartridges in early forks. I don’t think you have to race to benefit from quality suspension. I’m not any kind of pro but I put a hundred miles a day on my XR(when its not snowing) and stock BPFs are not that good. Cartridges make a huge difference. I went with a different brand but the man wants Ohlins. Corey if I were you (selfish me talkin) I would spring for the BPFs, get the Ohlins cartridges installed, and be confident you have the best!! If you’re good at selling stuff get the package and pass the shocks off on some poor sucker. Geno’s pic is where they belong. $600 for those shocks is a total gouge!
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CoreyDSFA
Thank for the advice all. I highly doubt that eBay sell of the X Rear Shocks will go at that price. Also there is a set of BPF Forks for sale as well. Once I send KFG the BPF Forks, they will be back to me in about 2 weeks.

Dwight hit the nail on the head. Going the extra mile for anyone else wanting Ohlins in their Non-BPF Forks, I am buying and giving KFG a new fork cap to aid them in the tooling. They will have the tech notes once a run is made. I do t have to do this, but I am so close to getting them, but do t want to wait 2 months or so, to get this done. Sometimes things take longer, and I don’t want to miss a memorial ride the end of March, and then ride around with a few other XR Owners in my area prepping for the Epic Ride, wherever it might be.

I know of someone else that wants these Ohlins in their forks, now they snd others will have more options. Glad to help with information, while I am getting something that I really want.

Again, that you all for your suggestions and thoughts; besides, I am getting tired of texting the letters KFG, and BPF. 😜
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