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Well, I have had my Expert for a week now and had to make some changes. Renthal Fatbar 800mm, 40mm rise, 31.8 Renthal Apex stem 50mm Shimano Saints 203mm front and rear. I tried really hard to get used to the Code R brakes but they were loud and took a ton of effort to get any real power out...

Great now we know the fork is working right, huck away!

LOL, sorry wasn't meaning you don't know how to measure its the fact that some of the Forks come wrong from the factory and don't actually get full travel. Most fox forks won't actually go all the way to the top of the stanchion and max out at lettering of Kashima. So I always do a manual check...

Fox forks do need a bit of breaking in before they feel great. Have you tried letting all the air out of the fork then fully compressing it so you know where bottom out is? Once you do this you will then know where to measure to verify what travel you are getting.

My local shop can did the custom tune.

You are going to be at the upper limit of what the stock fork and shock can handle. The best thing I ever did was get custom tuned. Almost all bikes come tuned for the 150lb-180lb rider. To your original question on my 2019 Levo expert I run 285psi rear and 104 psi front and weigh in at 230lbs...

I think you might not have enough pressure in the rear so your bike is sagging more to the back and causing the front to be light. Sag is just a starting point and is not a hard rule that it must be at 25%, 30%, etc use it as your baseline and adjust pressures to get the ride like. So I would...

Well after over a year keeping an eye on the e-bike world, watching EMBN, and Rob's videos I finally pulled the trigger on a 2019 XL Expert. Ebikes are not big here yet and I am one of few that rides 5-6 days a week on my trail bike to buy one, the comments of me being a cheater are constant...

Can you post what has changed in the different firmware versions, it would be really helpful to know. It would also be good if we can update the firmware on our own since all you do is plug the TCU into a computer with a USB cable.