Re-springing 900SS forks for a Monster 800

[Mr Earl]

I have a set of the '99-'01 900SS Showas, fully adjustable.  Bought a set of 0.85 kg/mm Race Tech springs, which came with a ~20" section of thin-wall 6061 aluminum tubing and washers, for spacers.

Issue #1: The Race Tech web site says I need "FPSS 02 spacers (not included in spring kit)"  Does anyone know what these are?  I've called Race Tech 4 times in the past 3 days - they don't return messages, at least mine.

Issue #2:  The new springs are slightly smaller in diameter (OD & ID) than the ones that were in the fork tubes - which were the stock progressive-rate ones.)  I'm worried about the new ones hitting the stock valve when the forks compress.  Any FHE out there?

Issue #3:  I'm a newb at fork tear-down.  Assuming a "typical"spacer set-up, would the spacers go under or above the spring?

Much thanks for any help on this.

[Speeddog]

#1 - I don't know what those FPSS 02 spacers are, but I'll try to find out.

#2 - Specifically, which part# springs did you get? FRSP S3732 085?
       If those are the ones, they very likely won't clear the plastic 'cup' thing that's on the damper rods.
       You can either remove the cup, or *lightly* grind the ID of the small end of the spring.

       Even with that, the smaller diameter of the spring allows it to drag on the damper cartridge.

       That's what I've found when respringing Monster forks, the SS forks may be a bit different.

#3 - Spacers go on top of the springs.

Those springs are shorter than the Monster springs, and I suspect they're shorter than the SS springs as well.

You will be in the ballpark on preload if you make a spacer such that the new spring + spacer is the same length as the OEM spring.

Whereabouts are you located?

[Mr Earl]

1.  OK, thanks, Speeddog

2.  Yep, that's the number. Here's a link with photos of a '97 fork.  In the 2nd photo, left side of the page, the rear spring/tube thingy combination is what I found inside the forks I have.  The valve is midway on the damoer rod? which runs down the center and attaches to the fork cap.  Are you thinking that the spring will hit the valve?

3.  OK, thanks again

The RT springs are shorter than the stock springs, by 1.75".  I made a spacer using a tubing cutter at 1.625, plus a washer on each side = 1.75".  Installed the spacer on the top of the spring (+ new oil), reassembled.  When I compressed the fork, it clicked at about the 1/2 point of the travel.  That's when I started investigating and found the RT notation aout the FPSS spacers.

When I put the springs in the tube, and they slide past the valve, there doesn't seem to be a problem with clearance.  I thought maybe the spacers on the bottom would better center  the springs on either side of the valve.

Man, this was supposed to be a quick re-spring and I'm back in bidness...

I'm in Colorado, just outside Denver.

[Mr Earl]

Duh, forgot the link:

http://www.teamyikes.com/SuperSport/sssuspension.html

[Speeddog]

OK, thanks, I was just going to ask about the link. 

One end of the RT springs is wound a bit smaller diameter.
The small end is supposed to go on the top.
Trouble is, it doesn't clear the plastic cup.
Sorry, I don't have access to my pics of fork parts right now...

I've got some OEM ST2 springs, they're about .84, and I suspect they'd drop right in.
If you're interested, I'd be willing to trade them + $, for your .85 RT springs.
They're 368mm long, 38.6mm diameter in the middle, 37.1mm diameter on the ends.

[Mr Earl]

Turns out I installed the RT spring upside-down, which I found out after disassembling the fork again.  Any chance that's what caused the clicking?

Do you mean the plastic cup at the base of the long metal tube that sits above the spring?  If so, wouldn't a spacer go above that with the RT springs?

Are the ST2 springs single-rate?  I'm interested in your offer, but this whole thing has to be put on hold while I go on family vacation until 6/22 - and I'd kinda like to hear what's up with the RT spacers, if the springs are not wide enough...

[Speeddog]

Clicking is probably the damper cartridge hitting the spacer washers.

Yes, that's the plastic cup I'm talking about.
Wish I had my pics available...

Yes, the ST springs are single-rate.

I'd like to know what's up with those spacers too.

There's no hurry, I'll still be here. 

[DesmoDog]

Duh, forgot the link:

http://www.teamyikes.com/SuperSport/sssuspension.html

Or you could just post the pic.   



Those are my forks BTW. I haven't even gotten them set up though... sucks being too busy to ride...

[Mr Earl]

Got back to work on the forks today.  My carefully considered opinion is Race Tech sucks.  These springs are just too small - the ID won't clear the damper rod valve.  I couldn't re-assemble the fork, because, as I compressed the spring, the damper rod/valve got pulled down along with it! (I put spacers at the bottom to avoid the clicking.)  The only possibility I see is to install the RT springs upside-down, but the ID still barely clears the valve.

Speeddog, would you measure the end ID of your ST2 springs for me, please?  If they'll clear the valve, I'd like to work a deal with you on them.  All the other dims you provided will work fine.

FYI, the RT springs I've got are 0.85 kg/mm, box says 37mm x 34.5mm x 315mm.

Thanks!

[Mr Earl]

Bumpity.  Speeddog?

[Speeddog]

Sorry for the delay.

ST2 springs are 1.06" (26.9mm) ID, both ends.

That's only about .005" smaller than the OEM progressive springs found in non- S4, S4R, S4Rt forks.

[Mr Earl]

Speeddog, those should fit perfectly.  Please PM me with what sort of deal you would make on them.  Thanks!