I can't help you on summer passing, but I will Mic my springs. If it looks like yours are larger, I will ship you these old ones. Like you, I'm busy as well and it will be Sept 1 ish. Almost everyone has swapped the front springs surely someone has a set they can measure the coil thickness. I would think cogent would know the stock spring specs. If I recall they are .40 kg/mm. I do not recall a length or coil dia spec in any of the reading/research. All the straight aftermarket rate springs are around .60 to .70 kg/mm for the klr application( at least the ones around a 200# rider from an actual suspension specialty shop).
My NE fork springs are 4.5mm dia and I found out the 08-14.5 fork springs are 4.2mm dia. Thank you for the offer on the springs, but I have a set on the way. Cogent did not know the stock NE fork spring rate, by the way.
However, I have made progress. I rebuilt the forks with 5W oil and I put the stock springs back in, as my older springs won't be here for a week or so. Stock springs with 5W made a great difference in fork plushness, as we would expect. Having now changed all the stem, suspension rocker arm, and swingarm bushings/bearings/bolts/washers, and rebuilt the forks, I put the panniers, drybags (350, 260), and topcase fully loaded on the bike and tested it on my street's sloping curbs. It oscillated like a fish in the first four feet of ride. I pulled the top case and drybags off and tried it again. It was worlds better with just the loaded panniers. The panniers loaded are 60# total combined plus racks, the drybags total 31# (and are on the passenger seat), and the top case was 16#. It was surprising that the relatively light topcase could make such a drastic change, but it is located high and behind the rear axle so it does make sense that it would have an impact disproportionate to its % contribution to the total load weight. These quick tests told me that the problem was on the subframe somewhere. I pulled off the panniers, racks, drybags, and top case mount and other parts and inspected the subframe. No cracks and the subframe bolts were solid. Interestingly, I was able to grab either handle on the stock rack, standing behind the bike and facing forward, seat off, and move them up and down and make the horizontal subframe bars between the tank and the stock rack flex...ever so slightly. This isn't the problem, though, just an interesting observation.
I then tested the bike, now with only front SW Motech crash bars and no racks, drybags, panniers, or topcase/topcase mount. No oscillation whatsoever when I rode diagonally up and down my sloping "test" street curbs. Also, the static oscillation I described in posts above, where previously when stationary I was able to cycle the bars back and forth quickly and the entire bike would oscillate for several seconds, was totally gone.
I will now take it to the local dirt bike area in this "naked" configuration and do a several hour ride to confirm the elimination of the oscillation with no panniers, drybags, racks, or topcase. I will then put the racks and panniers on with current load in them and confirm the degree of oscillation, if any, in that configuration. Then I will add the drybags and check the degree if oscillation.
1. If the naked test and the rack/drybag/panniers tests *all* have no oscillation: it is my topcase/topcase mount. Note I am using an EMGO topcase that clips to a plastic mount that is screwed on to the stock plastic rack and stock puny steel plate . Possibly there is a lot of side to side flex in all those plastic parts. A more solidly mounted top case (and properly loaded) may cure the topcase problem. For now, though, I will just not use a top case.
2. If the panniers as currently loaded, with drybags and with no top case, cause any oscillation, I will weigh the front/rear of the naked bike with half a tank of gas and get the actual front/rear weight distribution as the bike came from Kawi. I will then winnow down my camping load from the current 110# and try to create a camping load distribution that allows me to retain the front/rear weight % distribution, via some or all of: swapping the Tusk panniers for soft bags, loading heavy items in my crashbar SW Motech 8L bags, installing my tool tube on the frame down tube and actually putting tools in it, or possibly using tank panniers (though I admit these look goofy).
Pictures attached because this thread is wordy! Fully loaded near Bodie, CA, and also now with panniers, drybags, and top case stripped...and a bunch of invisible new bolts, washers, bushings, and bearings!
Onward and upward.....