I just swapped out my stock springs and I have a question about the spacer length. I followed the steps for calculating the length of spacer needed (I used 20mm of preload) and I got 81mm. I don't think this is long enough, when I lift the front end off the ground, the forks slide down quite a bit. I know the stock spacer is 200mm, but what should the new spacer length be around? I plan on pulling everything apart and remeasuring, but I'd like to have a reference point.

You don't say what kind of springs...

For sonic springs .85 rate I figured about 5.05" or 128mm.  Do a search on my posts for spacer length and you'll get several threads if you need them.   

I'll do a search, see what I can find.

I have race tech springs, .85 is the rate

Ahh.  Race techs are probably a different length.

Preload for straight rate springs (if properly selected for your weight) is typically 3/4". The threads on the fork caps are about 3/4" deep, so the spacer would come to the top of the fork top when then is no weight on them. It may vary some depending on your riding preferences. The actual length needs to be determined on your bike with your springs.

Quote from: dgyver on March 28, 2008, 05:39:36 AM
Preload for straight rate springs (if properly selected for your weight) is typically 3/4". The threads on the fork caps are about 3/4" deep, so the spacer would come to the top of the fork top when then is no weight on them. It may vary some depending on your riding preferences. The actual length needs to be determined on your bike with your springs.

That's the thing though, when I put the spacer in the fork in didn't come to the top. It wasn't even close, so I'm going to remeasure. I'm thinking it should be in the 125-130mm range, judging by my search results.

If the stock spacer is not long enough to shorten, cut a new spacer.

Did the springs even come with any instructions or replacement spacers to cut?

Quote from: dgyver on March 28, 2008, 09:37:01 AM
If the stock spacer is not long enough to shorten, cut a new spacer.

Did the springs even come with any instructions or replacement spacers to cut?

Yeah they came with basic instructions, but I was following the how to from the f.a.q. They came with spacer material also, which I cut up already. So I remeasured and I calculated a spacer length of 184mm, the springs must not have been all the way to the bottom of the forks. So now I'm going to cut the stock spacer.

Quote from: dgyver on March 28, 2008, 05:39:36 AM
Preload for straight rate springs (if properly selected for your weight) is typically 3/4". The threads on the fork caps are about 3/4" deep, so the spacer would come to the top of the fork top when then is no weight on them. It may vary some depending on your riding preferences. The actual length needs to be determined on your bike with your springs.

I cut my new spacers and they are pretty much even with the top of the fork tubes.  But for the life of me, I can't get the cap threaded back on. I press it down and start spinning, but it won't catch the threads. Is there a trick to get it started? Or any helpful ideas? My fingers hurt...

I've heard the trick is to... Turn the fork cap counter clockwise until you feel the end of both threads click, then turn clockwise until tight.

Quote from: groff22 on March 28, 2008, 01:41:24 PM
I've heard the trick is to... Turn the fork cap counter clockwise until you feel the end of both threads click, then turn clockwise until tight.

And use the palm of your hand, not your fingers.

I'm thinking I should pull the forks off the bike so I can try and get the cap on that way, I'm really having a hard time getting at the cap with them on the bike. Plus that way I could use my palm.

After dgyver checked out my bike,he pointed out that I had to much sag and I promptly reset the sag at 3/4 of an inch.I listened to everyone else and just added pvc caps to my forks.It wasn't enough.I have progressive springs tho.

I have 20mm of preload, which I think is 3/4". Finally got the caps on, taking the forks off really helped. Haven't checked my sag yet, but if it is too much, I'll have to buy more spacer tubing.