With only a little over 5 inches of total travel on the front forks, any sagging due to older springs or heavier riders,(me), becomes an issue that needs attention.
Inside the top of the fork leg is a thinwall steel tyube that is the preload spacer for the system. I lathed out a couole of one inch booster spacers to fit.
The outside diameter was 1.285" and the end wascot to a perfect fit inside the original tubular spacer 1.200".
If you do not have a metric wrench of propert size, a 1 1/8th wrench fits perfectly. put a THIN coat of bearing grease on the rubber O-ring of the cap. Fit the spacer into the spacer and set the cap on top.
Generous thumb pressure is required while feeling for the thread to begin fairly. The photo shows how to this with minimum pain.




Phelonius

Progressive doesn't have a listing for fork springs for our motorcycle, but has anyone checked their spec sheet to see if some fit?
http://www.progressivesuspension.com/pdfs/7100-105.pdf

Or, does anyone have a spare spring around that they can send to Progressive...if Progressive is interested...and find out of any will work or if they'll wind springs for us?  I'd take part in a group buy if Progressive was interested.

I have heard about the PVC fix, but being the basic paranoid that I am, I worried about the plastic deforming under pressure.
By making them out of steel, I have more piece of mind about that.
Besides, this way I put a shoulder on that keeps it centered on the original spacers.

Phelonius

When you get fork springs from progressive they come with pvc spacer,I put them on my suzuki 1500 and the front rides better.

bill67 wrote on 05/07/09 at 15:40:36:


Plastic is fantastic but steel is real.

Phelonius

Phelonius wrote on 05/19/09 at 09:36:25:

 It takes longer for plastic to rust

Phelonius wrote on 05/23/09 at 11:04:13:


But you dont "FILL" the forks full of oil, and you would need to hit alot of hard bumps to keep the top slashed with oil, it does get oil but not if its sitting or just tooling around town.
PVC spacers in forks are not subjected to much heat, no UV light and if you use the right thickness wont have any prob holding up to the little Savage...
PVC to me is easy to cut, lay a bit of sandpaper on a flat surface and twist, it will even out and make them flat, a little unlevel is ok as the spring will flex to it, just get the even.

Here's another trick to ease the task of replacing the fork caps against spring pressure.  You must first "clock" them:

Before inserting the fork springs, place each fork cap in place and turn until the threads just start to "catch."  Place marks on the cap and the top of the fork tube so that you can replicate this position.

After the fork springs are in, position the fork cap so that the marks you made earlier are lined up.  Press the fork cap down and start twisting.  The threads should "catch" immediately and you will not damage them.