Progressive Suspension Monotube 2004 Sportster Front End Upgrade

Improving the performance of a stock 2004 Sportster with the installation of Progressive Suspension Monotube fork tube cartridges. We also changed the stock 21" front wheel to 19".

[@npaisnel]

I was about to do mine this morning, then got called to work. Bike is on the lift with oil draining.
I too wondered about not taking the forks off... or even removing front wheel... oh hang on.. axle in the way of the cone/damper bolts.
Thanks for this video.

[@240LTS]

Seems simple enough. Although I worked on all parts of all my dirt bikes from 1969 to 1985 for Motocross, Hare Scrambles, Enduros and GNCC, I somehow am apprehensive to work on my 2004 1200C. Not sure why. I dislike the stock front springs as they bottom out hard on some bumps and have massive sag. Changing from the 21" improves handling in the turns I take it? Funny how all the dirt bikes have 21" front wheels.
Google is how I found your video. Nice job. Straight to the point w/o a lot of fluff.
I'll have to check the Progressive Suspension Monotube fork tube cartridges.
Thank you.
Jeff (Maryland)
.

[@BikesBuiltBetterHorsham]

The 100/90-19 front wheel/tire does turn more easily than the larger-diameter 21" front wheel. It's also beefier and less prone to destruction if you hit a pothole. Thanks for the kind words.

[@npaisnel]

Did you add any of the black C shaped shins to lift the height a little?
I was thinking about using one per side.
I weigh about 190lbs. Standard 2004 XL883.
Put Progressive 444’s on the back too. Was upset with Progressive, as the eyes at either end had no metal bushes... So I measured up, put the old springs back, and started to make my own bushes on the lathe..... only to then find the bag of bushes in the box ! Doh....

[@BikesBuiltBetterHorsham]

We did not add any of the shims. Rider weight was under 150 lbs

[@npaisnel]

Thanks
Maybe I’ll add one

[@TheLoneWolf_andCoyote]

did it make a night & day difference?

[@jayscorner5387]

With this kit, are original fork caps used?

[@BikesBuiltBetterHorsham]

No. There are caps attached to the Monotubes.

[@mroj2444]

Hi. I have a Sportster seventy-two 2015 with only 5000 miles. The front fork makes a clankc in extension and stains the bars a bit. I want to install these monotube. Should I change the seals or how these monotubes work with very little oil is not necessary ?. Thank you!

[@steelhorsecountry5245]

I have a 2006 1200 Custom might do this mod. Do I keep The my stock front fender? Can I use a Dyna 19" or just Sportster? When going to 29" is the front spring height more or same height as 21" So is the rake on Sportsters all the same?

[@BikesBuiltBetterHorsham]

Yes, you can keep the stock front fender. If the Dyna wheel has the same width and bearing size, it should work. I believe all 2004-up to about 2010 Sportsters have the same rake. Not sure what you mean about the spring height .

[@CactusJack252]

Did this give you more suspension travel?

[@BikesBuiltBetterHorsham]

No, it's the same. Have not figured out how to do that, short of grafting an Africa Twin front fork to the Sportster.

[@Dude_Virus]

I have the same sportster but a 2017 model. Want to know if this cartridge kit ia better or getting progressive springs better? Is there a way to get a longer spring length to reduce sag?

[@BikesBuiltBetterHorsham]

For most people the Progressive springs are a better deal. They use different length spring spacers to adjust the sag, and cost much less than the Monotubes. If you ride a LOT of miles (like 10,000+ per year) the Monotubes will save you money on maintenance in the long run.

[@Dude_Virus]

@@BikesBuiltBetterHorsham Thank you for the information, yeah I do ride quite a lot during the year BUT that is not my main concerns for upgrading the forks. There are a lot of bad roads within the city and in general. So i want to upgrade to counter act those as well as to reduce the dive while braking.

[@BikesBuiltBetterHorsham]

@@Dude_VirusWhich city?

[@Dude_Virus]

@@BikesBuiltBetterHorsham Bangalore in India

[@BikesBuiltBetterHorsham]

@@Dude_Virus Holy cow. Oops! Sorry. I was expecting New York or Chicago...Well, I have been working on that Sportster in the video. Tried the Monotubes (too stiff for a 140-lb rider) the Progressive Springs with various weights of fork oil...finally bit the bullet and had Traxxion Dynamics install their $1200 conversion. Still too much hammering from the forks. I'm about to ask them for lighter weight springs. At this point I wish I had known about the guys who built a Sportster for the Baja 1000. I'm starting to think that the big issue is just not enough travel for the lousy roads. I've been wondering if a set of forks from a Honda Africa Twin could be transplanted to a XL. That bike has a similar weight to the late Sportster, but it's got something like 8 inches of travel. That's as far as I've gotten for now; I'm just out of money.