xr400 spring swap with 2004 kdx220r

http://dirtrider.net/forums3/search.php?searchid=222391

That should help ya. Or do a search in the forum called "preload spacers"

ELF

Spacer

In a nutshell you need to make new spacers. Use 1" schedule 40 pvc. To determine the proper length, put springs in fork tubs and put the farok cap all the way. Measure the distance between the bottom of the fork cap and the top of the spring. Now add to this measurement any amount of preload that you want. I used 4mm but it is a preference thing.

Finally, and this is no joke, make sure that when you put everything back to gether you hold the fork cap in place and twist the fork tube against the fork cap to tighten. Some who have just tightened the fork cap had clicking noises in the forks when complete. The thought is that by only screwing in the fork cap puts tension on the spring.

For what it is worth.

Mark

Everything you have been told above is correct. Preload depends on personal preference based on rider weight, ability (speed), and spring weight. Some, including me have used 10mm of preload which should give you about an 1.5" spacer. The 4mm mentioned above is about a minimum preload for you don't want the spring jiggling around loose in the fork. So that said, anything you choose between 4 and 10mm preload should give you a great ride! Easiest and best mod you can do for the money!! Ride safe - this mod will help you do that- John

don't forget to use a torque wrench on the axle cap nuts or you may snap the studs off

Da!!!!

Yeah, don't be stupid and read the manual specs as foot pounds instead of inch pounds as is written. Who would be dumb enough to misinterpret the manual. Some idiot.

Mark (the idiot who can't read the manual)

There is one thing missing. Assuming you put the oem spring-centering washers back in (the cupped/flared washers that were on either end of the long metal oem spacer?), you have to figure them into the equation.

If you have 4mm of space when measured as directed, if you use both washers (about 3mm) and want 7mm or preload, your spacer would be 8mm. 8+3-4=7 You will be happier (IMO) with a good deal less preload than that (considering your spring rate choice to be correct in the first place), say 3-4mm.

Make sure the spring seat that came out with the old springs (it's clipped to the bottom of the spring) gets secured to the new springs. Well...to start with..make sure the things came out in the first place! If they didn't, get 'em out.

Consider a lower oil level. 100mm is considered 'normal'. It's a matter of personal choice...mine is 115/120.

Do yourself a big favor. Buy a set of MotionPro (or other brand of your choice) bleeders. Use 'em often (3-5 times on a day's ride).

spacers

I made 7/16" (11mm) spacers and all is well. I weigh 170 without gear.