Fork spring guides - 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 11 Old 03-21-2019, 11:37 AM Thread Starter
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Fork spring guides

So I lost my fork spring guides, and really don’t want to wait till someone stocks them,
Was thinking of using a fender washer and short nut and bolt, any ideas?
Thanks


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post #2 of 11 Old 03-21-2019, 01:45 PM
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what part are you talking about?

https://www.ronayers.com/oemparts/a/...front-fork-a7f

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post #3 of 11 Old 03-21-2019, 01:57 PM
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I think a fender washer and bolt is not a real good idea.

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post #4 of 11 Old 03-21-2019, 02:38 PM
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agreed. I'm not sure you'd need it with a 3/4" PVC spacer......needed with the thin stock metal spacer, no doubt......just thinking out loud; best to get another set.

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post #5 of 11 Old 03-21-2019, 03:59 PM Thread Starter
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my thinking is that a flat head machine screw through a fender washer, w/bolt down in the spring would act as the protruding center section of the original guide, that and the tension from the spring would keep it from migrating off of the top of the spring


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post #6 of 11 Old 03-21-2019, 07:40 PM
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Those are nothing more than a simple Flat Fender Washer! All it has to be is slightly smaller OD than the ID of the upper fork leg. NO bolt, nut or machine screw to guide ANYTHING! The upper end of the springs can't GO anywhere, they are rigid against the spacer, which is against the top cap.

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post #7 of 11 Old 03-21-2019, 10:20 PM Thread Starter
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Quote:
Originally Posted by DPelletier View Post
agreed. I'm not sure you'd need it with a 3/4" PVC spacer......needed with the thin stock metal spacer, no doubt......just thinking out loud; best to get another set.

Dave


How long does the 3/4” spacer need to be?


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post #8 of 11 Old 03-21-2019, 10:33 PM Thread Starter
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Fork spring guides

Quote:
Originally Posted by pdwestman View Post
Those are nothing more than a simple Flat Fender Washer! All it has to be is slightly smaller OD than the ID of the upper fork leg. NO bolt, nut or machine screw to guide ANYTHING! The upper end of the springs can't GO anywhere, they are rigid against the spacer, which is against the top cap.

They look like this, thus my thought on the screw/bolt...


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post #9 of 11 Old 03-22-2019, 09:28 AM
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You are working on the stationary end of the spacer & spring. As long as the OD is near the proper size, a flat washer will be just fine.
Nothing can really slip or slide out of place. Others have suggested that it is not even 100% necessary.

Or you can order the genuine original part.
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pdwestman
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post #10 of 11 Old 03-22-2019, 09:49 AM
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How long does the 3/4” spacer need to be?


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that depends; you should set the spacer length (preload) for the right amount of sag (2.5" +/- .25" on a Gen1). To get there, you will probably need to add some length so I'd start by measuring the stock spacers and adding .5" .....assuming that you don't happen to have the right sag at your weight and loading with the stock spacers and springs.

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