Fork Spacer Length - 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 7 Old 11-13-2019, 03:17 PM Thread Starter
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Fork Spacer Length

I'm new to the forums and I'm sure this question has been beat to death. But what length do I need to cut the PVC spacer for my forks. I have a 2006 KLR 650 with about 7,000 mi on it. I live in Arizona and take advantage of the awesome trails. Before my forks would bottom out. I recently installed a set of progressive springs. I emailed Progressive and they told me to cut the spacers to 2 inches which I did in addition to putting in Maxima 10wt fork oil. In the rear I have a 8kg top gun spring on the stock shock. I also ride two up with my wife. I've read a lot of forums and the recommended spacer lengths I see are all over the board. Your help would greatly be appreciated. Thanks Greg B
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post #2 of 7 Old 11-13-2019, 03:52 PM
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The spacers are used to set sag and as such vary depending on springrate and load. I don't use progressive springs so I can't help you there but I'd suggest trying whatever length the spring manufacturer suggests and then modifying as necessary from there - PVC is cheap. You should be aiming for 30 - 33% sag which on a Gen1 with 9.1" of travel is 2 3/4" - 3".


Or you can buy a set of fork preload adjusters.... https://www.motocd.com/product/adjus...load-fork-cap/

Dave
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post #3 of 7 Old 11-13-2019, 11:48 PM
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I had progressive springs before my cogent setup and I just put in whatever they said to. I remember it being 2 or 3 inches. I think I cut a few different ones to try.

Just go with their recommendation and cut it down a bit more if it is too stiff.

It ain't an exact science.
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post #4 of 7 Old 11-18-2019, 06:23 PM
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Originally Posted by DPelletier View Post
Or you can buy a set of fork preload adjusters.... https://www.motocd.com/product/adjus...load-fork-cap/

Dave
Or you can go "cheap Charlie" and buy these for less than 50 bucks.

Jason
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post #5 of 7 Old 11-18-2019, 06:43 PM
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Or you can go "cheap Charlie" and buy these for less than 50 bucks.

Jason
sure but i bet you don't get any free lifesavers with those!

Dave
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post #6 of 7 Old 12-02-2019, 06:28 PM
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Quote:
Originally Posted by Greg B View Post
I'm new to the forums and I'm sure this question has been beat to death. But what length do I need to cut the PVC spacer for my forks. I have a 2006 KLR 650 with about 7,000 mi on it. I live in Arizona and take advantage of the awesome trails. Before my forks would bottom out. I recently installed a set of progressive springs. I emailed Progressive and they told me to cut the spacers to 2 inches which I did in addition to putting in Maxima 10wt fork oil. In the rear I have a 8kg top gun spring on the stock shock. I also ride two up with my wife. I've read a lot of forums and the recommended spacer lengths I see are all over the board. Your help would greatly be appreciated. Thanks Greg B
Suspension is one of my favorite topics and one I have quite a bit of experience with. I've helped set up quite a few KLR's with Progressive springs. What you want to try and obtain is Race Sag. Google "Paul Thede Race Tech Race Sag" and read his article. It will give you the basics. I would suggest a length of 6" to 7". 10wt is a good starting point. Oil level affects the last 20% of suspension travel. As such small adjustments can make big changes. You want to use as much of the fork travel and have occasional light bottoming. Service manual gives you the ranges. Make no more than 10mm change. Fact is much of the woes with the front forks is actually caused by the poor rear shock...even when it has a stiffer spring added.
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post #7 of 7 Old 12-03-2019, 09:53 AM
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Fact is much of the woes with the front forks is actually caused by the poor rear shock...even when it has a stiffer spring added.

Iím a believer. When I put on my Cogent rear shock and hit the pavement on my ride home the constant ... clomp ... clomp ... clomp was reduced to near nonexistent little bumps. Even on the front-end that I hadnít changed out yet. That was a big surprise to me.
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