Progressive Drop in Kit

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Sep 22, 2012 | 08:36 AM

#11

fatboy1729

Road Captain

Joined: Aug 2007

Posts: 602

Likes: 12

From: Ma.

Quote:

Originally Posted by jreichart

It technically is a "drop in" kit on all models in that the fork tubes themselves don't need to be disassembled, just removed from the bike. In comparison to the full kit, which requires complete fork tear down to add damper springs which accomplish the drop, this kit is quite simple. Remove the forks, remove the caps, take out old springs, insert new springs, reinstall on bike. I installed the full kit on mine, and it is quite a bit more involved, not to mention additional parts like seals, caps, crush washers, bushings etc...

Hey J, thanks again for the quick tips. Will I still be changing out the oil or can I leave it alone after the new springs are in? Also thanks for your time reading all the posts on this.

Sep 22, 2012 | 09:01 AM

#12

jreichart

Road Warrior

Joined: Mar 2011

Posts: 1,918

Likes: 5

From: Heber Springs, AR

Quote:

Originally Posted by fatboy1729

Hey J, thanks again for the quick tips. Will I still be changing out the oil or can I leave it alone after the new springs are in? Also thanks for your time reading all the posts on this.

Since you'll have it all apart, probably a good time to change the oil. Many who have done the drop have changed to the heavy fork oil for better damping and improved stability. I installed ricor intiminators on mine, so I stayed with the light oil per ricor specs. I would also use the fill method outlined in the manual, a bit more accurate than just using ounces. The manual provides a measurement from top of tube to top of oil with the fork vertical, springs removed and the tube fully extended. Remember to slowly cycle the shock a few times when about half way full to make sure the oil is getting passed the damper. You can also just dump the oil out the top, rather than mess with the drain screws which can be a bit tough to get resealed if all you have is a screwdriver. On mine, the drain screws are a #3 Phillips, so don't try your standard household screwdriver (#2) or you'll strip it. If you do need to remove the drain, put a #3 Phillips insert bit (the short kind you'd use in the drill/driver) into a 1/4" socket, and use the socket wrench to remove/reinstall. It'll provide more torque than a screwdriver handle would.

When reassembling, be sure to heed all the torque specs for the various fasteners, and evenly tighten the axle clamp nuts on the right side of the wheel, there should be an even gap on both sides of the clamp. For the fork tube fill caps, I found that placing a microfiber cloth over the nut and using an adjustable wrench over the microfiber worked well and prevented the finish from getting all buggered up.

Good luck, and don't forget to post up pics when it's all done!

Sep 22, 2012 | 02:21 PM

#13

hawaiian

Thread Starter

Novice

Joined: Sep 2010

Posts: 15

Likes: 0

Hey Thanks Guys for all the info on this thread,it really is helpful. Appreciate your time and wisdom. Tutu would say knowledge is what you know but wisdom is learned by doing.

Feb 19, 2014 | 07:51 PM

#14

Mr Hosehead

2nd Gear

Joined: Dec 2010

Posts: 6

Likes: 0

From: SoCal mountains

Easy but time consuming...

Thought I could just unscrew fork cap and bingo...no problem. LOL
Like your shop manuel says (you need this for proper torking on reassemble) take the lights and chrome sheet metal loose after removing bars (use towels to protect tank and fender). Support front end and remove wheel, caliper and fender. Loosen fork cap and remove then loosen top pinch bolt and lower fork down enought to remove spring retainer fitting with open end wrench. Spring will POP out so use shop rag or towel as back stop. Remove spring and install new spring and washer. Cut spacer to specs provided for your bike and close it up. Not much pressure so don't worry. (You can screw on fork cap into retainer and screw in retainer with socket to make it easy. NO SPECIAL TOOLS REQUIRED). Reassemble and add oil per manual. You're gonna like the ride!

Feb 19, 2014 | 08:17 PM

#15

strapped

Advanced

Joined: Aug 2012

Posts: 80

Likes: 0

From: Virginia

I did the drop in on my Deluxe not long ago it wasnt to bad but a little longer than I thought I think it was about 3 hours the hard part was removing the headlight and the chrome housing be sure to cover your fender with something I also got away without removing the handle bars.Not the best pic but 2 inch drop