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lesjive said:
Try screwing that little nipple back up into the cap til it comes in contact with the adjuster knob, then, keeping pressure on the nipple, turn the adjuster knob CCW and hopefully it will grab the nipple part and suck it back up.
The worst case is you'll have to disassemble the whole thing. Easy to take apart, a real ***** to get the spring and balls back in. I've used tweezers to hold both balls in while installing the knob, doing it over a big kitty litter style tub helps from loosing parts.
There should be nothing attached to that rod when you pull it out. It's just a big long rod that pushes down on the rebound components further down in the fork.

I don't know what you mean by "nipple". I got the threaded portion, coming from the top of the spring guide, the rod is inside it, protruding a few mm, the cap is still a mystery, is that what you're talking about taking apart?
 
I think I see. I read your first post again, Les, and watched the video. He has a pair of thin pliers ("special tool") that he used to hold the threaded tube. When the cap is down, he still has space between the top of the spring guide and the cap, that's clear in the video. Mine is not like that, it threads right up against the nut atop the spring guide and bottoms there.
 
No, that wasn't it either. Spring guide was threaded all the way down.

Incidentally, with everything pushed down, like in the Slavens video, I can put a tiny tape measure down 140 mm before "striking oil".
 
Sorry to hear your still having problems, frustrating too say the least.
Do you have any KTM riding friends in your area?
Forks are the same, maybe they could shed some light.
Or you could take a week off, fly on over to N.Cal and we could sort it all out .. :wink:
Trails are just above freezing in the Sierra's- the sound of ice crunching under your tires is kinda therapeutic this time of year.. :bounce:
leaves.jpg


BTW, gotcha Bushy- my curt reply was meant for Taffy's post.
Taffy, here's an example of my look on life..
P8080027.jpg

Or, I could just go with the EVIL eye..
face.jpg
 
Nice pics, Les. I'm learning as I go, and I'll get it sorted out or send it off. The only frustrating things are, I should have been doing this in November and discovered the problems then, since I'm going to miss my race it looks like. That, and paying someone a nice chunk of change to do it wrong.

I'm gonna take the other one apart tonight, see if I can decipher the mystery of the cap. When I turn the adjuster, something should change, unless there are fine threads in there that are boogered up. That's why there's a plastic knob, so you won't bottom out the rod and strip the threads.

The first time this bike came from this guy, I had to use pliers to turn the plastic knob on one side. That may be the cap I'm dealing with now, that doesn't seem to work at all, it may have gotten broken back then.

Someone called late last night (eastern time), it was probably Dale. I was already out.
 
Taffy said:
the rebound assembly has been put together in the wrong synch.

remove the fork cap from inside the leg and then also off the shaft. you'll need to pull the spring down and put a 22mm open ender on it and then a 24mm on the top nut.

when all undone you need to turn the rebound anti-clockwise till you have the black plastic inside all the way up and deeper than the copper threads you can see.

if nothing is turning it is because the black knob has disconnected from the black nipple underneath.

so pop the adjuster up with a couple of flat bladed screwdrivers.

now 2 ball bearing COULD ping off so I suggest doing this using a vice and a plastic bag over the cap. use the screwdrivers to dislodge the adjuster then cover with the see-through bag a remove. you'll see 2 x 2mm ball bearings and a tiny spring.

so back to what we needed to do before: use a philips screwdriver to get the nipple higher so when you put the adjuster back in they are connected.

yer man's problem is that the two disconneted from each other.

when refitting you always have the nipple as deep as you can so you can see the copper coloured threads. then refit the cap on the shaft and tighten the spring guide up, then the cap down and in the fork.

then you adjust the rebound all the way closed (to zero) and then re-open the set amount.

this is what he failed to do.

regards

Taffy

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maybe this only works if you're revving the bike really really hard ? kinda like a sonic screwdriver
 
Next question

Next stupid question - everything I've seen shows setting fork oil level relative to the top of the outside tube, so I assume the "110 mm", "115 mm", etc. is measured from the top of the outside tube, correct?

I was told it was measured from the top of the inside tube. I have to think that if this were true, it would be pointed out clearly any time it came up, since that is counter-intuitive, and contrary to the demonstration pictures or video.
 
Re: Next question

OldNewbie said:
Next stupid question - everything I've seen shows setting fork oil level relative to the top of the outside tube, so I assume the "110 mm", "115 mm", etc. is measured from the top of the outside tube, correct?

I was told it was measured from the top of the inside tube. I have to think that if this were true, it would be pointed out clearly any time it came up, since that is counter-intuitive, and contrary to the demonstration pictures or video.

That would depend on whether you have conventional or USD forks. Remove spring, fully compress the fork, and measure down from the top to the oil surface, be it inner (conventional) or outer (USD). Simplest to use a syringe and tube, slightly over fill, put a zip tie on the tube at the level you want, and suck out to the level required.

Steve
 
Thanks, Steve, that makes sense.

If the forks are conventional, the top tube would be the inside tube, and it's going to protrude when pushed all the way down, and you measure from there.

If the forks are USD (up side down), which mine are, then you again compress, measure from the top of the highest tube, which in this case is the outer, or upper tube.

Do I have it?
 
OldNewbie said:
Thanks, Steve, that makes sense.

If the forks are conventional, the top tube would be the inside tube, and it's going to protrude when pushed all the way down, and you measure from there.

If the forks are USD (up side down), which mine are, then you again compress, measure from the top of the highest tube, which in this case is the outer, or upper tube.

Do I have it?

I believe so :idea:
 

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