Fork Spring Replacement

1980 XJ650 Maxim
Seeking advice from those who have passed this way. I bought a set of progressive fork springs to install, replacing the OEM saggies. The OEM springs are close 25" long (specs say 23.89, but they aren't anymore), and the progressive replacements are 19". WTH! I called the manufacturer. They confirmed that these are the correct replacements, and said I had to "fabricate spacers" out of PVC pipe. So, has anyone been here done that? If so, what length did you cut the spacers? Do the spacers go below the springs?
It is never simple is it?

I greatly appreciate all advice and feedback.

 

It is standard practice to make spacers from PVC, and it works fine. There should be instructions with your springs telling you how to measure for spacers. The spacers go on top of the springs, they are the last thing before the fork cap goes back on. Besides the fork oil.
For most forks I have done the spacer needs to provide 1 inch of pre load. Meaning the spring needs to be compressed 1 inch before the fork cap goes on. You will have to assemble your forks with springs then measure for the spacer. The spacer is usually sticks out of the fork tube about 1/2 inch.

 

Correct..... Follow the instructions. What you are doing is adjusting the preload.

 

Many thanks for the advice all. Hum - never realized how handy a home improvement store was for motorcycle repair parts...

 

if you put a coupling on the cut end, you'll have a nice square end. if it fits in the fork ?

 

Miter box. Cuts square every time.

 

I think he meant this:

 

That's a cap for a cleanout. He meant this:

 

I know it's a cap.... I assumed that's what he meant by "a nice square end". Ok, I guess I should have read it as " a nice and clean, squarely-cut end"

Lol

Btw, I was rather surprised to realize there are clean-outs that small..... Guess that explains why I've never actually seen one ..... But Then i haven't had to look for a clean-out that small, either

 

I missed a joke. Dang..... something must be done to correct that.

A lot of commertial sink traps have clean-outs now. The p-trap is cemented so it's less likely to leak.

 

Nope... No joke, I just misunderstood the original intent of " square end "

 

Mission accomplished! Thanks for all input. 1 schedule 80 3/4" X 10" PVC pipe nipple, miter saw for square cuts at exactly 4 1/2" inches in length, new progressive spring in first, 1/2" flat washer in next, then the spacer on top. The spacer extended 1/2" above the tubes. Repeat. New Bel-Ray juice in the forks. Cap on, clip in. The front end now feels fresh and new, not like a trampoline. A good ROI here both safety and comfort.