I've had my Progressive springs for damn near a month now and I've been procrastinating and haven't taken the time to install them.I need a little info before I feel confident to start the project.
First; what size is that big *** nut on the top of the 49mm forks ? I measured it at 1 and 3/8 inches is there a metric equivelant? I have a 32mm it looks close but I won't be able to check it out till I pull off the bars.
Second how much fork oil do I need to buy? And it would really be usefull if somebody measued how much oil in ounces or ML goes in each leg, I know the instructions say 5.5 inches but just knowing the amount of oil would be allot easier than pour, measure,pour measure etc.
The Progressive kit didn't come with washers, are there some already in the forks or do I need to buy some of those too?

 

hey man i figured i would give ya all i have and maybe some of it will help....

as far as socket sizes i dont remember, butonething i can tell ya is to install the 1' not the 2' unless you want the thing dragging the ground... i put the 1' in in and if i wasnt low enough for me i was just gonna lower it with the tubes in the trees.... but i think mine is plenty low enough...

sorry man not much help but i just wanted to give you my .02

 

sorry i cant help much either i have no patiants and used a cressant wrench but i did go 2" and it doesnt drag its just real close

 

Service manual says just over 26 ounces per fork. It doesn't list the wrench size for the top bolts, but 32mm equals 1.259".

 

With the stock components in the tubes, Harley calls for the fluid to come 4.3" from the top, which is approximately 26.6 ounces in each tube. Your set-up needing to be 5.5" from the top will require a little less oil. While 3 pints may do it, I would buy 4 pints to make sure you have enough.

 

Here is my contribution to the discussion, First off let me say I did mine but it was an 07 WG so I am not sure of the oil amounts being the same. Yes 1 3/8 is the right socket, I would recommend using the socket over the cresent wrench due to the fact that the plugs are fine threaded and are very easy to cross thread. Ifound one at the local tractor supply store, but was for a 3/4 in drive so I had to buy a reducer for a 1/2 in socket wrench. Secondly don't drop the plugs on the cement floor it will booger up the threads causing you to go on a three state search for a replacement (don't ask me how I know). I would recommend a new set of seals when you reassemble they are cheap and make sure you install them spring side down (once again don't ask me how I know but suffice to say they don't work worth a chit upside down). You will need a 12mm allen wrench for the bolts in the lower legs. They are kind of a bitch to get apart and I would recommend using an impact wrench to reinstall I couldn't get them tight enough by hand andended up taking by fork tubes to the localHD and letting them snug them up. Next the dust covers on top of the fork lowers arejunk, i bent the crap out of mine reinstalling them and ended up buying a replacement set that has a small set screwvs. being pressed on. You will need a piece of 2in pvc to use as a seal driver. When youmeasure your spacers for the progressive set makesure thatyou make your measurements with the forks fully extended otherwise they will be way too short. My service manual says 29.6 oz of fork oil or 4.4 in from top measured with forks fully extended. I also usedscreaming eagle heavy fork oil much better. I think that about sums up all my woes from doing the springs, bottom line I f/up a couple times b/cof stupid crapoverall not a bad mod andif I had to do it again it would be a piece of cake. The up side is that the improvement in ride and feel is very much worth it, bike rides great and does not nosedive when hitting the skids. Hope this helps if you have any otherquestions let me know and I will help as much as I can. Good luck

 

Yep it is 1 3/8 inches. My 32mm did not fit. I had to buy a new socket. I have found recently that there is a socket designed for the HD fork cap which is shallow to get in under the handle bars.

 

OK guys thanks for the info. I'm not using thier lowering kit just swapping out the stock springs for Progressives.So what I've learned so far is I need an 1 and 3/8" socket, two quarts of fork oil, and so far it looks like I'm going to have to measure the oil level from the top down with some kind of dipstick.Now what about those washers?The box I got came with spacers pre cut to size and springs and nothing else, other than instructions.

 

I am not sure about the washers as I went back with the stock springs. I think the washer goes between the spacer and the spring. The stock set up has a metal spacer inside. As for the oilmeasurement I just used a standard metal tape measure. Instructions state that the tubes have to be fully compressed when measuring.

 

Used the stock washers.