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[QUOTE="grump99, post: 1079838, member: 45183"]
I think you are on the right track.  I installed the later model xr 400 springs in my kdx.  With the rod fully extended I had about a 1 mm gap, maybe 2.

I could be wrong here, but I think the correct way to set the spacer length is by front race sag (assuming you have the correct spring rate for your weight).  I read somewhere that about 70-75 mm of sag is ideal, but dont quote me on that.

As an example, I weigh 180# without gear.  Initially I used about an 8 mm spacer (about 5 mm of preload).  My race sag in the front ended up about 90-95 mm.  I felt that this was too much sag, because it felt like the bike was riding too low in the fork stroke and would nose dive upon hard braking.

I then went to an 18 mm spacer (about 16 mm of preload).  That gave me about 60-65 mm of race sag.  I liked the change much better.  Much less nose dive and the front felt much more balanced with the rear (although a little harsher over rocks and such).  My next step will be to try about 10-12 mm of preload.

The point I'm trying to make is that pvc is easy to cut to length and is pretty cheap.  You should try different lengths and find what works best for you.  As a start maybe try 1/2"
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