Got the springs in the post today. They're roughly about 15mm shorter than the stock. Does that sound about right?
Also, what's the torque setting on the spring bolts?
Nope, that doesn't sound right. I hope you mean 1.5mm.
What I measured, per the table above, was ~31.8mm for a KLR600, ~37.2mm for a 2008 650, and ~33.8mm for the Barnett. Note that the 600 and 650 springs were used and sacked to below the service limit.
Kawasaki changed the springs in 2011, but the overall length remained the same, with a service limit of 38.7mm. You should be comparing the length of the springs to the service limit. They did change the torque spec on the bolts, from 89 in-lb
to 81 in-lb
I'm not quite sure how they took two elements out of the stack and maintained the same spring OAL, but for the fact that the stock spring is pretty weak. Maybe it all works out. Or maybe the factory manual is wrong again. Flying a bit blind here.
If the springs are shorter than service limit by 1.5 mm I wouldn't worry about it too much. The spring rate on the Barnett springs is twice that of the stock spring in the Gen 2 <'11 application.
Specifically, what are you seeing as a measured OEM spring length? I'd love to know the OAL, wire diameter, and outside diameter of your springs. It might help understand what the different part number means on the >'11 springs.