Progressive 512 Series Utility ATV Suspension System
By Mike Batchelor
After we got our project Honda Rancher one of the things that began
chafe our hides – literally – was the rock-solid, non-adjustable
suspension. The stiff springs allowed the nimble Honda Rancher AT
to handle like a sports car, but the tradeoff was a ride that would
absolutely shake the fillings out of your teeth on rough trails.
Well, our dental plan sucks and we needed to do something
fast so we called Progressive Suspension and explained our
plight. The folks at Progressive
Suspension agreed that the last thing the 4X4Review needed
was another toothless editor so in the interest of dental
hygiene they shipped out a 512 Series Utility ATV suspension.
So what makes the Progressive 512 Series suspension different
than it’s OE red-headed cousin? Progressive rate springs
and gas-charged, velocity sensitive shocks. Progressive rate
springs use variable density windings to allow the spring
to react differently at various levels of compression. Under
light compression the tightly wound section near the end of
the spring allows the suspension to be rather soft, which
takes the edge off of bumps. The looser windings in the middle
of the spring are firmer so they provide a tight and controlled
ride when the springs are compressed further. In short, the
springs are nice and soft during your average ride, but the
progressive spring rates will stiffen things up a bit with
heavy loads, or during the landing that follows your Super
Man impersonation.
The other big difference is the fact that the Progressive 512 Series
suspension provides a spring preload adjustment. Why Honda
left this off is beyond me, as nearly every other competitive
ATV offers a preload adjustment and it couldn’t cost
more than a few dollars per shock to add - so what gives Honda?.
The preload adjustable springs are wrapped around gas charged
shocks that use velocity-sensitive dampening to help provide
a smooth ride and reduce shock fade – a situation that
you do NOT want to happen during high-seed runs. (Click
here to learn more about how shocks work)
Yet another benefit to the Progressive Suspension is that
it provides an additional inch or so of much needed suspension
travel. Finally, each Progressive 512 shock/spring combo comes
with a durable and removable “Shock Sock” which
helps protect moving parts like the piston and seals from
dust and grime.
The installation of this suspension system is so easy, it’s
not even worth a detailed outline. To do so however, start by safely
jacking up the ATV, then do away with each of the OE shocks and
springs by removing the bolt at each end. Replace them with the
Progressive shock and spring combination and reinstall the bolts.
Having someone to lift the rear end is helpful, but otherwise this
is a one person job that should take less than 45 minutes from start
to cleanup.
Once we had the Progressive 512 Series suspension installed
– a few laps around our test track quickly revealed
an astonishing improvement in ride quality and control. It
was like graduating from a go-cart to a rally car. The Rancher’s
ultra-firm OE stock suspension provided go-cart handling,
but the penalty was that the jolt from every bump, rock and
dip was transmitted directly to the seat and handlebars. The
Progressive 512 series suspension, on the other hand, gobbles
up trail imperfections like Pac Man goes after pixels, without
sacrificing ride control. The result is a much softer ride
with no loss of stability or predictability. The ride is also
much less fatiguing and the improvement in control and predictability
translates to an improvement in safety and fun.
So what’s not to like? Zip, nada, nothing. The suspension
was easy to install, the price was fair (about $350 for a full set
of front and rear shocks), and the improvement in ride and handling
was simply phenomenal. Whether you use your ATV for work or play,
I can’t think of a single upgrade that is easier to install
and provides as much of an improvement in performance for the money
as the Progressive 512 Series Utility ATV Suspension.
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Click thumbnails for larger images
The Progressive 512 Series suspension system
uses progressive rate springs. Note how the windings are closer
together at one end.
The stock suspension compared to the Progressive
512 Suspension. Notice that the new suspension is about one and
a half inches longer than the standard suspension.
The stock suspension uses standard springs.
The oil dripping down the shock is the result of a failed seal.
Installation of the new shocks and springs
was a snap. Removal and replacement only involved 2 nuts and bolts
per shock.
The front suspension was just as easy to install
as the rear.
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