I ordered some Jitsie springs for my 2005 Gas gas Raga 300 but when I came to fit them they are about 1" shorter, but more importantly they are 5mm narrower. This makes them to narrow for the plastic spacer tube.

 

Has anyone incountered this problem or are they the wrong part for my forks?

 

Link to the springs

 

 

 

 

numbers on my fork leg.

 

Those springs should be stiffer due to the reduced diameter, you need a small spacer turned up to take up the space. This spacer will also act as an adaptor to pass the load into your plastic spacer, I would suggest a spacer with the following dimensions

1/ O/D same as your plastic spacer

2/ I/D same as the I/D of your new spring or smaller

3/ Length, to make up the difference in the springs

4/ You could also put a small raised collar on the spacer to fit inside of the existing spacer to lock them together making your assembly easier.

OR just make up a new spacer to do the whole job in one !

Those springs should be stiffer due to the reduced diameter, you need a small spacer turned up to take up the space. This spacer will also act as an adaptor to pass the load into your plastic spacer, I would suggest a spacer with the following dimensions

1/ O/D same as your plastic spacer

2/ I/D same as the I/D of your new spring or smaller

3/ Length, to make up the difference in the springs

4/ You could also put a small raised collar on the spacer to fit inside of the existing spacer to lock them together making your assembly easier.

OR just make up a new spacer to do the whole job in one !

 

Is that how to bodge the wrong part on, or just what you must do to fit stiffer springs? I would rather have the right parts to be honest.

It is not a bodge, it's called engineering, I have ridden pre 65 bikes for 10 years so I have got used to it.

Any mate with a lathe will sort you out.

Aparently there are 2 diffrent types of 40mm Marzocchi forks for the gasgas 2005. So the springs are wrong.

I would say the smaller OD springs are for the 40mm Aluminium upper fork legged Marzochhi's, (found on later model Gas Gas and Scorpa SY's) because they have a reduced diameter in the section between the triple clamp uppers and lowers.  Hence a narrow OD spring would be used.

The larger OD springs would be from an earlier Marzochhi set with Steel uppers that were a consistant 40mm OD all the way up the tube.

Looking on the Jitsie label it does not specify which set of Marzochhi forks they are for, so there is the mistake I would guess.

Hi

 

I have been thru this exercise on my gasser as well.

 

The length of the springs is different, as stated I just got a new spacer, just enough to take up the slack in the fork.

 

As for the diameter not sure of that but it doesn't matter as either way you will have to make up a new spacer.

 

Hope that helps.