Contributed by Josh Leonard (aka Qheuie)

The pictures here were taken when i was replacing the original inserts i had made (1 3/4") with shorter ones (1")
(just pictures of the left fork leg)
The diameter of PVC coupler to use is 3/4". The coupler is 2" long so you will have to cut it down.
Make sure you debur the plastic after you cut it. You probably don't want plastic flakes floatin around in your fork.


Here I took the bars off.. simple enough. Then I loosened the clamp pinch bolts by the caps, make sure you do this or turning the fork caps out will be a pain.
I also took the bolts that hold the cable guides to the fork off so i could move the bars out of the way.
(an old pair of jeans worked great to catch spills and protect the paint)



This is how much the spacers stuck out when I opened the fork (there is a 1 3/4" spacer in already,
sorry for the dark image :)



This is what the stack of spacer(s) and washer looked like before i put it back in. Notice the order of insertion.
I made sure to put the "factory" (non-cut) side of the PVC down to meet the spring, the washer meets the cut side then.
(the washer is between the PVC and the metal.)



This is the stack sticking out just before i capped it with a 1" spacer (1 3/4" was too stiff for me)
Notice the difference in material hanging out (about 3/4", ha)



This is where the fun began. When i put in a 1 3/4" spacer, i had to have my roommate help me push and turn the cap in.
The 1" spacer was manageable by just myself.
Tip: thread the cap on without the factory spacer in just to find where it "catches" the threads in the fork. That way you can make a good guess as to where to start turning the cap when compressing the stack. (Did that make sense??) Make sure you don't cross thread the cap/fork tube! You can feel when the cap starts to thread, if it turns easy you are ok. If not, try again until it turns in easy


I repeated this procedure for the right fork leg and then put it all back together and torqued the bolts with my spanky new Craftsman torque wrench :)



I thought this was a neat, cheap upgrade. For the money it seems to help reduce sag quite a bit. I didn't like the feel of the 1 3/4" spacer so i went to a 1" spacer. I think 1" is going to be too soft, so i may go to a 1 3/8" spacer next. Also, i used the tool kit that cam with the bike (yucky). If you have a 22mm 6 point socket or wrench, i would recommend using it on the caps.