Well here is a fork diameters list
I know the KLR600 forks are disc and are probably on your rubbish list but maybe some decent pads, forksprings, emulators and braided line would make them work to your liking??
Maybe the 84/85 XR250? Im not sure what caliper they have but if they are single piston, maybe a dual pison one can be fitted?
38 Honda CR-125R (81-83)
38 Honda XR-250R (84-85)
38 Kawasaki KX-80R2/R3/R4/R5/R6/R7 (92-97)
38 Kawasaki KX-125 A6-A7 (80-81)
38 Kawasaki KDX-200 A1-A3 (83-85)
38 Kawasaki KX-250 A5-A7 (79-81)
38 Kawasaki KDX-400 A1-A2 (79-80)
38 Kawasaki KX-420 A1-A2 (80-81)
38 Kawasaki KL-600A1 "KLR" (84)
38 Kawasaki ZX-600C1-C6 "Ninja" (88-93)
38 Kawasaki ZX-600C7-C10 "Ninja 600R" (94-97)
38 Kawasaki KL-650A1-A18 "KLR650" (87-04)
38 Kawasaki VN-700A1 "Vulcan" (85)
38 Kawasaki VN-750A2-A20 "Vulcan" (86-04)
38 Kawasaki ZX-750F1-F4 "Ninja" (87-90)
38 Kawasaki ZL-900A1/A2 "Eliminator" (85-86)
38 Kawasaki ZX-900A1-A3 "Ninja" (84-86)
38 Kawasaki KZ-1000C1-C4 "Police" (78-81)
38 Kawasaki KZ-1000J1-J3 (81-83)
38 Kawasaki KZ-1000K1/K2 "Ltd" (81-82)
38 Kawasaki KZ-1000P1-P20 "Police" (82-01)
38 Kawasaki ZL-1000A1 (87)
38 Kawasaki KZ-1100A1-A3 (81-83)
38 Kawasaki KZ-1100B1/B2 "GP" (81-82)
38 Kawasaki KZ-1100D1/D2 "Spectre" (82-83)
38 Kawasaki ZN-1100B1/B2 "Ltd" (84-85)
38 Suzuki RM-125 N/T/X/Z (79-82)
38 Suzuki RM-125 D (83)
38 Suzuki PE-175 Z/D/E (82-84)
38 Suzuki RM-250 N/T/X/Z (79-82)
38 Suzuki RM-400N/T (79-80)
38 Suzuki LS-650 FG/PG/FH/PH/PJ (86-88)
38 Suzuki LS-650 PS/PT/PV/PW/PX/PY/PK1/PK2/PK3 "Savage" (95-03)
38 Yamaha YZ-125 H/J/K (81-83)
38 Yamaha IT-175 J (82)
38 Yamaha IT-175 K (83)
38 Yamaha IT-250 H/J (81-82)
38 Yamaha YZ-250 D/E/F/G (77-80)
38 Yamaha FZR-400 U/SUC/W/SWC (88-89)
38 Yamaha FZR-400 A/SAC (90)
38 Yamaha YZ-400 D/E/F (77-79)
38 Yamaha IT-465 H (81)
38 Yamaha IT-465 J (82)
38 Yamaha YZ-465 G (80)
38 Yamaha XT-550 J/K (82-83)
38 Yamaha FZR-600 W/WC/AC/B/BC (89-91)
38 Yamaha FZR-600 RA/RAC/RB/RBC/RD/RDC/RE/REC (90-93)
38 Yamaha FZR-600 RF/RFC/RG/RGC/RH/RHC/RJ/RJC (94-97)
38 Yamaha XJ-600 SD/SDC/SE/SEC/SF/SFC/SG/SGC "Seca II" (92-96)
38 Yamaha XJ-600 SH/SHC/SJ/SJC "Seca II" (96-97)
38 Yamaha FZX-700S/SC/T/TC (86-87)
38 Yamaha XJ-700N/NC/S/SC "Maxim" (85-86)
38 Yamaha XJ-700 XN/XNC/XS/XSC "Maxim" (85-86)
38 Yamaha XV-700L/LC/N/NC "Virago" (84-85)
38 Yamaha XV-700CS/CSC/CT/CTC "Virago" (86-87)
38 Yamaha XV-700 J1/J1C (97)
38 Yamaha XV-750 U/UC/W/WC/A/AC/B/BC "Virago" (88-91)
38 Yamaha XV-750 D/DC/E/EC/F/FC/G/GC/H1/H1C/J1/J1C "Virago" (92-97)
38 Yamaha XV-1000 L/LC/N/NC "Virago" (84-85)
38 Yamaha XV-1100 S/SC/T/TC/U/UC "Virago" (86-88)
38 Yamaha XV-1100 W/WC/A/AC/B/BC/D/DC/E/EC "Virago" (89-93)
38 Yamaha XV-1100 F/FC/G/GC/H/HC/J/JC "Virago" (94-97)