Anyone chop their fork springs??

I have a 01 650r, and I am looking to do the suspension (Borynack style). Im wondering if anyone has chopped their stock spings and used spacers instead of buying new spring? How much do you cut them? What do you use for spacers? Geared up Im right at 200lbs. so Im going with a .45kg fork, and 10.0kg shock spring.

My thought process is if I buy new springs, Im just going to throw away the stockers,, might as well try to cut them just to see if I can do it real cheap. Then add new springs later if I dont like the results.

Thanks

I have done this several times on many different bikes and it seems you have to cut a little more then calc'd out. A little over 2" is about the limit you can cut and use spacers before you get spring bind at full compression. That seems to "Feel" like under .47kg/mm like it was suppose to be. We have messured this and it is close to .46kg/mm (hard time getting a true messurement) Hope this helps. Don't forget that almost .25" is spring that is not being used, that you are cutting off.

http://www.off-road.com/dirtbike/tech/2002spring/

http://www.xr650r.borynack.com/

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Thanks for the advice, froze my fingers riding to work today,, supposed to be cold for a bit, so bike is being torn down now

BWb are you Bruce B?? If so Thanks for the help. the fork page on www.xr650r.borynack.com Has some great info about compression valving..:thumbsup:

I have done this several times on many different bikes and it seems you have to cut a little more then calc'd out. A little over 2" is about the limit you can cut and use spacers before you get spring bind at full compression. That seems to "Feel" like under .47kg/mm like it was suppose to be. We have messured this and it is close to .46kg/mm (hard time getting a true messurement) Hope this helps. Don't forget that almost .25" is spring that is not being used, that you are cutting off.

http://www.off-road.com/dirtbike/tech/2002spring/

http://www.xr650r.borynack.com/

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yeah...

next time I'll read the whole thread first

Just did the operation today,, went real easy. I took just a hair under 2" off, only takes a couple minutes with a torch and bench grinder. Better to go a bit long,, you can always take more off,, havent seen an article about welding springs back together to make them longer.........I guess we'll see how it works when I figure out what I want for valving, and find the shims to do it with. Thanks again Bruce

I am working on making aluminum spacers for the XR650R that will hold the spring and fit in the cap. That will cut out the noise in the forks........lots. When you cut the springs and put a spacer in the spacer rests on the side of the fork tube most of the time as dose the spring and makes noise. If I get around to making the shims I will make them a standered size of 50mm, that will have perch to hold the spring, perch to fit into the fork cap.

I found my solution, bushings from an old Yan ski lift. Almost the perfect size, length was perfect, diameter could have been 0.5mm more but oh well. put everything back together today, except to make it easier to tighten the locknut on the piston rod, I put the spacers in under the spring. I couldnt think of any reason not to, other than getting them out later might be a PITA. Cant wait to ride it to work tomorrow

I found my solution, bushings from an old Yan ski lift.

I can't begin to tell you how many parts from Yan's lifts are on different projects around my shop.

You work on a ski resort by chance?

Yep,, Snowmaking Mgr for the place on the hill..... by the way,, took the bike out today for the first run on the rebuilt forks, it was awesome,, eats up the small stuff that used to really rattle me, and still feels good on the bigger high speed stuff. Cant wait to give it the full test at Johnson Valley this weekend

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