So, stripping to the frame for powdercoating is out. I am back on refinement of the front-end to get my G/S in top shape for the comming national rally in OR:
OK, to re-cap where my G/S front suspension is at today:
1999 KTM 640 WP Extremes shortened and installed - otherwise completely stock
Tried running 5wt and 10wt fork oil, now on 7.5wt
With all these weight I rode a number of miles varying the adjustments on the comp and re-load from nothting to max
None of the weights of oil nor setting on the valves gave me a plush and controlled ride (like the Ohlins shock out back does). All were a compromise and right now with mid-level adjustments on the comp and pre-load with 7.5wt the front end has a cavitation (?) and gently hops while riding on pavement... the front wheel was balanced when the new TKC was installed.
So, where are we today? The forks are in my car and headed to Konflict Motorsports to Alex who I got my custom .055 springs from for some valving adjustments, seals and such. Turn around time will be ~2 weeks.