Andreani 39mm fork cartridge upgrade Pt 1 of 3

Super Sporty Suspension

Andreani 39mm fork cartridge upgrade

This is the Andreani 39mm fork cartridge conversion kit as seen unpackaged and ready to install.

Words: Chip Kastelnik Photos: Mikey Van Senus

Italian superbikes are known for their incredible handling. One of the main reasons these bikes handle so well is the way the suspension is set up for each bike and its rider. Andreani has taken this state-of-the-art technology that is used in the superbike industry and came up with a drop-in, tunable cartridge kit for 39mm H-D forks for XL. The result is a responsive front end that reacts well when put to the test. We installed the cartridge kit in our “Little Devil” Sportster project and were quite happy with the results. Unlike other fork kits, the Andreani cartridge setup requires some special tools and general suspension knowledge to install properly.

Andreani 39mm fork cartridge upgrade

We begin by taking apart the front end of our Sportster, beginning with taking off the front wheel.

Words: Chip Kastelnik Photos: Mikey Van Senus

Andreani 39mm fork cartridge upgrade

Next, we slide each fork tube out of the triple trees.

Words: Chip Kastelnik Photos: Mikey Van Senus

Andreani 39mm fork cartridge upgrade

Loosen the fork dampener bolts.

Words: Chip Kastelnik Photos: Mikey Van Senus

Andreani 39mm fork cartridge upgrade

Flip each fork over and allow the fork oil to drain into a drain pan. Compress and expand the fork in order to remove the fork oil in the fork tube.

Words: Chip Kastelnik Photos: Mikey Van Senus

Andreani 39mm fork cartridge upgrade

Carefully pry the rubber dust cover off of the fork lower.

Words: Chip Kastelnik Photos: Mikey Van Senus

Andreani 39mm fork cartridge upgrade

Using a small flat-blade screwdriver, pop the oil seal snap ring free from the groove in the fork lower. After removing the snap ring, remove the oil seal and fork lower.

Words: Chip Kastelnik Photos: Mikey Van Senus

Andreani 39mm fork cartridge upgrade

Using a JIMS USA fork cap remover, take off the fork cap in order to remove the spring. Be careful when taking the cap off, as the spring tension can force the cap upward, and that can be bad if it hits you in the head.

Words: Chip Kastelnik Photos: Mikey Van Senus

Andreani 39mm fork cartridge upgrade

Remove the fork spring. Do this over a drain pan so residual fork oil can drain into a safe place instead of on the floor or on your shoes.

Words: Chip Kastelnik Photos: Mikey Van Senus

Andreani 39mm fork cartridge upgrade

The next thing that will come out of the fork tube will be the lower spring and the dampener. Place these parts in a safe place; they will not be used with the Andreani cartridge lit.

Words: Chip Kastelnik Photos: Mikey Van Senus

Andreani 39mm fork cartridge upgrade

Pictured here is the stock fork tube setup taken apart. We will only be using the fork tubes and lowers. The stock internal components will not be used.

Words: Chip Kastelnik Photos: Mikey Van Senus

Andreani 39mm fork cartridge upgrade

To install the Andreani cartridge kit we must first take the stock fork tubes and place them on the lathe in order to remove the bottom (lower) rolled edge that holds the stock fork tube internals.

Words: Chip Kastelnik Photos: Mikey Van Senus

Andreani 39mm fork cartridge upgrade

After removing the rolled edge, Tatro takes a solid-steel pole, which fits inside the 39mm fork tube inner diameter and drops it through in order to force the fork tube internals out of the tube.

Words: Chip Kastelnik Photos: Mikey Van Senus