Premium Suspension Kit Instruction Sheet - Harley
Contents
1. adjustment setting Table 5 Suspension Damping Adjustment Guidelines XR 1200X MOTORCYCLE BEHAVIOR SUGGESTED REMEDY Soft or unsettled feeling around corners or after bumps Increase rebound damping Leaping feeling or topping after large bumps Increase rebound damping Harsh sharp feedback over bumps Decrease rebound damping Feels like motorcycle drops down over chatter bumps Decrease rebound damping Excessive bottoming through potholes Increase compression damping Excessive dive when applying front brake Increase compression damping forks Hard feeling or inadequate absorption over bumps Decrease compression damping Feels excessively stiff or busy around corners Decrease compression damping J04909 MAINTENANCE Shock Absorbers These shock absorbers contain pressurized gas Visually inspect the shock absorbers while observing the following precautions WARNING Shock absorber cannot be serviced Attempting service can cause an explosion which could result in death or serious injury 00602d Do not refill disassemble puncture or expose shock to flames e Replacement and disposal should only be done by an authorized Harley Davidson dealer Front Forks The service procedure for these forks are different than other forks Refer to the service manual for XR1200X forks for inspection maintenance and service procedures 5 of 62. SERVICE PARTS is06108 Figure 9 Service Parts Premium Suspension Kit Table 6 Service Parts Table Item Description Quantity Part Number 1 TORX screw self tapping 3 8 16 x 1 5 in 4 4352 2 Front fork assembly left 48771 10 3 Front fork assembly right 48778 10 4 Shock absorber left 54671 10 5 Shock absorber right 54700 10 6 Amber reflector right 69861 07 7 Amber reflector left 69862 07 J04909 6 of 6
3. cMOTOR HARLEY DAVIDSON QU J04909 INSTRUCTIONS REV 2009 06 01 PREMIUM SUSPENSION KIT GENERAL Kit Number 54530 10 Models For model fitment information see the P amp A Retail Catalog or the Parts and Accessories section of www harley davidson com English only Kit is not compatible with saddle bags P N 90328 08 Additional Parts Required Separate purchase and installation of additional parts or accessories may be required for proper installation of this kit on your model motorcycle See the P amp A Retail Catalog or the Parts and Accessories section of www harley davidson com English only for a list of required parts or accessories for your model PINT N IN The rider s safety depends upon the correct installation of this kit Use the appropriate service manual procedures If the procedure is not within your capabilities or you do not have the correct tools have a Harley Davidson dealer perform the installation Improper installation of this kit could result in death or serious injury 00333a NOTE This instruction sheet references service manual information A service manual for your model motorcycle is required for this installation and is available from a Harley Davidson Dealer Kit Contents See Figure 9 and Table 6 REMOVAL Front Fork Assembly 1 Refer to the XR model section of the service manual and remove the front forks INSTALLATION Front Fork Assembly 1 Install front for
4. he rear shock absorbers INSTALLATION Rear Shock Absorbers 1 See Figure 3 Install the rear shock absorbers according to service manual instructions The shocks are installed with the external gas reservoir to the rear of the shock absorbers and the thick side of the grommet installed to the frame rail mounts Figure 3 Install Thick Side Of Grommet To Frame Rail SUSPENSION ADJUSTMENTS Front Fork Suspension Adjustment WARNING Whenever a wheel is installed and before moving the motorcycle pump brakes to build brake system pressure Insufficient pressure can adversely affect brake perform ance which could result in death or serious injury 00284a WARNING Adjust both forks equally Improper fork adjustment can lead to loss of control which could result in death or ser ious injury 00124c CAUTION Compression and rebound adjusting valves may be dam aged if too much force is used at either end of the adjust ment range 00237a J04909 NOTES Damping is set at the factory for the average solo rider under normal riding conditions The rider may make adjustments to compensate for individual riding styles and varying road condi tions Evaluating and changing the rebound and compression damping is a very subjective process with many variables and should be approached carefully The front and rear preload setting will need to be adjusted for the rider s weight and cargo This adjustment shou
5. ks from kit to motorcycle according to ser vice manual instructions but do not tighten the fork bracket pinch screws at this time 2 SeeFigure 1 Measure the distance from the top of upper fork bracket to top of fork assembly Both sides must be exactly the same and measure 0 388 0 468 inch 9 85 11 89 mm above the top fork bracket Align the adjustment screws inline with the handlebars see Figure 5 J04909 is06083a Figure 1 Fork Installation Height Measurement NOTE If new pinch screws are not readily available use a wire grinder wheel to remove all remaining lock patch from original pinch screws wash screws in clean solvent and dry thoroughly Apply two drops of LOCTITE 262 to the first 1 4 in 6 35 mm of the end threads 3 Install pinch screws to upper and lower fork brackets 4 Verify fork tube installation measurement is 0 388 0 468 inch 9 85 11 89 mm 5 Tighten pinch screws to 30 35 ft lbs 40 7 47 5 Nm is06209 Figure 2 Attaching Reflectors to Fork Sliders 1 of 6 NOTE See Figure 2 The top edge of reflector should be 1 1 2 inches 38 10 mm below the lower edge of the bottom fork clamp 6 Remove the adhesive backing Place reflector in position and press reflector firmly into place to activate the adhesive Repeat for reflector on opposite fork REMOVAL OEM Rear Shock Absorbers 1 Refer to the XR model section of the service manual and remove t
6. ld be made before the motorcycle is ridden any distance and after changing the overall vehicle weight adding saddlebags etc If the preload adjustment is correct and you have the rebound and compression damping set at the factory recommended points the motorcycle should handle and ride properly Changes in the load carried requires changes in the preload setting s Carrying less weight than was used for setting up the suspension requires decreasing the amount of preload Increasing the load carried requires adding more preload The following tools are needed to make suspension adjust ments 5mm hex key front fork preload adjustment tool Spanner wrench with extension handle shock absorber preload adjustment e Screw driver front fork damping adjustment 1 Front fork preload adjustment a See Figure 4 and Table 1 Using the 5 mm hex key turn the preload adjuster counterclockwise until it stops This is the minimum preload setting b Turnthe preload adjuster clockwise the recommended amount specified for the rider weight is06085 Figure 4 Fork Preload Adjuster 2 of 6 Table 1 Recommended Fork Preload Adjustment RIDER WEIGHT PRELOAD Less than 165 Ibs 75 kg 0 4 turns in 165 195 lbs 75 89 kg 4 6 turns in 195 225 lbs 89 102 kg 6 8 turns in 225 255 lbs 102 116 kg 8 10 turns in Greater than 255 lbs 116 kg More than 10 turns Values shown are clockwise
7. m aged if too much force is used at either end of the adjust ment range 00237a NOTE Do not force adjusters beyond the mechanical stops 1 Shock absorber preload adjustment a SeeFigure 6 and Table 3 Using the spanner wrench turn the adjusting cam 1 to the recommended posi tion as specified in Table 3 2 Shock absorber compression damping adjustment a See Figure 6 Using fingers turn the compression adjuster 2 clockwise toward the H until it stops This is the maximum compression damping setting b See Table 4 Turn the compression adjuster counter clockwise toward the S the recommended amount 3 Shock absorber rebound damping a See Figure 7 Turn the rebound adjuster counterclock wise toward the H until it stops This is the max imum rebound damping setting b See Table 4 Turn the rebound adjuster clockwise toward the S the recommended amount 3 of 6 is06087 1 Preload adjusting cam 2 Compression damping adjuster 3 Pressurized gas valve do not remove cover 4 Spanner wrench is06106 po 5 4 OURS 1 Minimum preload adjustment 2 Maximum preload adjustment Figure 8 Shock Absorber Preload Adjustment Table 3 Recommended Rear Shock Preload Adjustment Figure 6 Rear Shock Preload and Compression Damping Adjusters RIDER WEIGHT PRELOAD Less than 165 Ib 75 kg Position 1 165 195 Ib 75 89 kg Posi
8. tion 2 195 225 Ib 89 102 kg Position 3 225 255 Ib 102 116 kg Position 4 Greater than 255 Ib 116 kg Position 5 is06105 Table 4 Recommended Rear Shock Rebound and Compression Damping Adjustment XR 1200X DAMPING NOMINAL From Maximum Compression COM 7 clicks Rebound REB 5 clicks Figure 7 Rear Shock Rebound Damping Adjuster J04909 SUSPENSION TUNING NOTE After the preload and damping have been set to the recom mended settings additional adjustments can be made to enhance the comfort control and handling characteristics of the motorcycle These adjustments may be based on personal riding style desired ride quality and varying road conditions 1 Set the front forks and shock absorbers to the recom mended settings Properly inflate the tires 2 Determine the ride quality of the motorcycle Ride the motorcycle on a familiar road with a variety of bumps and turns Ride over different surfaces at varying speeds If the suspension is set properly the vehicle suspension will feel controlled and comfortable 3 See Table 5 Adjust the rebound and compression damping according to the motorcycle behavior experienced during the ride 4 After adjusting the suspension ride the motorcycle again to check for comfort and response 4 of 6 NOTE When tuning the suspension make all adjustments in small increments Radical setting changes may overshoot the best
9. turns in from minimum Rotate adjuster clockwise to increase preload or counterclockwise Table 2 Recommended Fork Rebound and Compression Damping Adjustment XR 1200X DAMPING NOMINAL FROM MAX IMUM Rebound REB 3 turns Compression COM 5 turns Values shown are counterclockwise turns out from maximum Rotate adjuster clockwise to increase damping or counterclock wise to decrease damping to decrease preload 2 Front rebound damping adjustment a SeeFigure 5 and Table 2 Turn the rebound damping adjuster clockwise until it stops This is the maximum rebound damping setting b Turn the adjuster counterclockwise within the range of turns specified to the desired setting 3 Front fork compression damping adjustment a See Figure 5 and Table 2 Turn the compression damping adjuster clockwise until it stops This is the maximum compression damping setting b Turn the adjuster counterclockwise within the range of turns specified to the desired setting is06086 AN 1 Rebound damping adjuster 2 Compression damping adjuster Figure 5 Fork Rebound and Compression Damping Adjusters J04909 Shock Absorber Suspension Adjustment WARNING Adjust both shock absorbers equally Improper adjustment can adversely affect stability and handling which could result in death or serious injury 00036b CAUTION Compression and rebound adjusting valves may be da
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