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enginenumber · Aug 13, 2010

hi there all,
just pulled out the .44 front springs in my 04 550 fe and just stuck some .46 springs in to see if they function better seeing I weigh in just over 100kg with gear on.
I dont know much about suspension, however I did notice the nylon spacers in the top that the spring sits against, were different in each leg.

On the brake side the I had a 1.5mm , 5mm and a 10mm nylon spacer
On the other leg it only had a 1.5mm and a 10mm

Is this like this or should they be even each side? What should I have in there?

philg · Aug 13, 2010

Try 0.48s with little to no preload - you can get them cheaper if you use MX ones which are shorter and just need a spacer to make up total length. - 20 mm from memory. The difference in spacers is the factory attempt to make different springs the same overall size. You may have to do the same when replacing springs you often find that they are 5 to 10 mm different lengths. At 100 kilo maybe 0.5s.

maicoxx · Aug 14, 2010

Hi i've got 2004 fe 550 and 100kgs don't know a lot either, but here's what i run .46 springs fork oil 130mm and back off the compression till it feels ok then work on the rebound to steady it up , i found a pds 8 rear spring which works well with sag 110mm bit of rebound and it all seems too work nicely . the other thing too do is trawl the suspension pages on the site invaluable info lurks in there........coli

Taffy · Aug 14, 2010

there is a small article in the doc about how to check the pre-load on the fork springs. they should be done individually. don't buy any, a few people around here have them in the shed if you need them.

I was told the 'sweet spot' is 4mm of pre-load.

I weigh 95KG naked and use 48s although I wish I had a 46 and a 48 now (=47s) so if anyone has some 46 left out of their swops I would like a set.

regards

Taffy

enginenumber · Aug 15, 2010

Just been out and tested it today with .46 springs.
After posting , i found the WP suspension book that came with the bike. Definately better. it has taken out a hell of a lot of harshness when hitting rock. Cant beleive I have been riding around so long on lighter springs, I have strained fore arms from the harsh springs. I will back the compression off next test. I run the fork 5mm up in the clamp so it turns better.I will also check the preload and spacers.The .46 springs were out of a 06 ktm 450sx, same length as well.

I will have to look at the rear spring also , to balence it all out. it has one up from standard in the rear 81-99/260 at the moment. I am sure if I do the rear spring it will sit up better and work well and turn even better.

I used to use the whole of the travel in the forks, now it stops 50mm before bottoming under normal riding. Backing of the comp. should allow it compress further hopefully.will check the oil level to.Is the oil level checking done with the spring in and compressed leg?
Thanks

bushmechanic · Aug 15, 2010

springs out

2 methods,

Dump method; bottom out the forks overfill, pump out oil to about the right height put rod in the cap replace cap fully extend forks remove cap pump out oil again. reinstall springs etc this is how it goes in the WP manual

no dump method: bottom out the forks make sure the gap between the chrome tube and the upper leg is full of oil then set the level.

no dump is supposed to be more consistent and quicker but allmost all the heights you find as specs will be for the dump method.

enginenumber · Aug 23, 2010

I have made the right move with just putting in the .46 springs,130mm gap and got the 4-5mm preload right by getting rid of some spacers. the front is so much different, tracks so well when turning and hitting rock , no deflection, harshness has gone, the front does not dive in whooped out ground either.Using all the leg travel still except for 3/4 inch at the end in normal riding.
Thanks for the input on that,4 years I have been riding on a wrongly sprung bike! I just tend to ride the thing and not fidddle with stuff to much.

Definately need to do the back end now, cant get any better than 116mm sag, so i would say that is causing rear end isssues.Will service the pds unit as that would have 300-400 hrs on it. Heavier spring and see how it goes.

Also Is there any true value gained in upgrading some of the internals on an 04 pds, or was most of that just experimental stuff people had tried.(Tappered needle), progessive spring, shim arrangements out of a later model and so forth?

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