fron fork spring dimensions - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 4 Old 01-30-2015, 02:20 AM Thread Starter
1st Gear
Join Date: Nov 2014
Location: port stephens, nsw
Posts: 43
fron fork spring dimensions

gentlemen I have a different one for you.
I decided to finally check the fork oil level on my 2003 euro type aussie KLR650 I bought just over a year ago.
Done a couple of rides and the front just wanted to wash out on gravel, but thought it was either me (likely) or the forks. Easy one is to check the oil level.
Haven't got pics but at the top was a home made shim stack made out of panel washers and nuts with a little hole in each washer. The little stepped washer for the top of the spring nowhere in sight.
Fork was using ATF (red so just guessing to suit the shim stack maybe) and one fork was only 90mm from the top (spring out, forks compressed), the other about 120mm. Oil level meant to be 190mm from factory, yes?
Anyway, how long is the spring and the spacer on these so I could at least make sure it is standard. I would like DDC's once money allows but want it to go back to spec for now. Could use slightly heavier oil to dampen a bit more but that's it.
Help please?
csmiffy is offline  
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post #2 of 4 Old 01-31-2015, 02:54 PM
4th Gear
Join Date: Oct 2013
Location: Chilliwack, BC, Canada
Posts: 1,481
I think the stock KLR650 Gen1 springs are 19-5/16" long. A smarter person would have tagged the springs I have lying around but think I measured Gen1 spring. Canadian 2002 or so was the bike, I think.
Normk is offline  
post #3 of 4 Old 01-31-2015, 06:16 PM
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 6,471
I've read that oil level of only 190 mm from top of tube, fork compressed, leaves the damper piston sucking air at Full Extension. Best to set oil level at 170 mm or higher. Probably 130-120 Max Height, don't want hydraulic Lock.

Standard spacer length might be a touch over 5.5 inches. Like Normk, lots of stuff With-out Labels!
Normk is correct on std spring length.

Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
pdwestman is offline  
post #4 of 4 Old 01-31-2015, 09:32 PM Thread Starter
1st Gear
Join Date: Nov 2014
Location: port stephens, nsw
Posts: 43
Well, took the springs and spacers out and measured. Springs close enough to 17", spacer was 8". 25 inches all up. removed funny shim stack from the top, sucked oil out so at 170mm from top of tube and put back together-hardly any preload on the spring though. Just have to take it for a ride to try
csmiffy is offline  
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