Fork Springs Challenge

[BigZCas]

Really would like some help again
Attached photo's are the springs from my Z1a.
Manual says replace if under 496mm but does not say what they should actually be ?
Mine measure 523mm, this seems a bit excessive ?
Also I have caps in the ends but can find no reference to these for a Z1a.
If I load springs without caps they stick out of the tubes by 15mm, if I leave the caps on they stick out 25mm because the caps do not slide over the innards (maybe).
The opening at the other end of spring is larger so caps would not be gripped.
Any body out there come across this ?

Cas

[z1bman]

standard length 495.5mm service limit 485mm

[ADRIAN H]

Standard spring length 495.5mm - Service limit 485mm.

[BigZCas]

That's strange, both Haynes and Clymer both agree for 73, Z1 but say service limit 496mm 74 / 75, Z1a & z1b ?
Have to know for sure and will cut down
Any idea on the caps ?
Thanks

[z1bman]

taken from the genuine kawasaki manual . your fork springs are not the original they are after market heavy duty springs

[BigZCas]

Do you think it would be ok to cut down to 496 and leave the caps off the ends

[z1bman]

if you are going to cut them you will have to use a slitting disc on a angle grinder then the end of the spring will need to be ground flat then you can still use the capped washers

[Coose]

Before you chop them I would fit them and measure the sag as it's not a black art and will potentially save you a lot of work. Anywhere between 35 and 45mm of laden sag would be fine.

[garyd]

I've got a pair of springs if you want them.

I'll measure them later today.

[zed1015]

They are HD springs and I would leave them in.
The stock suspension is soft as shit and these springs help the handling.
If you really want stock springs then buy some or trade with another member.
Cutting these springs won't soften them up but just reduce the preload and increase the static sag.
The spring rate will remain the same.

[BigZCas]

One of my concerns was that they protrude 25mm out of the fork stanchion and will prove difficult to get the fork tops started ?
Although someone must have got them in before

[zed1015]

All fork springs need compressing to some degree by the cap before starting the thread.
Done plenty and it isn't difficult, just make sure the fork slider is hanging free so it is fully extended (wheel off the floor if doing it with the forks in the bike).
Use a T bar and socket to help push the cap down squarely whilst turning.
To prevent any marking of the hex head by the socket use a bit of plastic bag between it and the socket.

[ZedHead]

It is good to see that good advise is still forthcoming from experienced people on this forum.

I agree about the HD springs. Zeds were always on the soft side.

[BigZCas]

Thank you everyone for your help and advice
After considering all, I have decided to use the same spings as removed and see how it goes on assembly.
Cheers
Cas

[garyd]

Hewre's something for the experts. I have two pairs of spring which I beleive came out of Z1000A1 forks.
They measure 465mm.

Did the internals change that much from the Z1?