Different rebound on front fork legs?

esvirta · Nov 12, 2009

I just changed the oil of the fork legs, and put both of them back together. I tried compressing each leg by hand and there seems to be much more rebound damping on the left fork leg. There is exactly the same amount of oil from the same bottle in each leg. I also checked that the preload adjuster was screwed all the way in when I assembled the legs.

Should there be a difference or am I worrying over nothing?

Thanks,
Eskil

esvirta · Nov 12, 2009

.. and the fork legs are from 09 FE 450.

bushmechanic · Nov 12, 2009

could be the lil delta shims on the mid not properly aligned

they also have the silly bleed shim on the mid, it screws with the rebound

could take it apart and check both legs but if it rides good its prolly OK.

if you're serious about rebound consistency the bleed shim should be moved one position in the stack away from the valve

esvirta · Nov 13, 2009

Thanks,
I'll check the shims.

Eskil

esvirta · Jan 4, 2010

Finally I had the time to check the shims.

I disassembled both forks completely, but I didn't find any misaligned shims or anything that could be the reason for uneven damping. I cleaned everything and put the forks back together. Now the forks feel even. I don't know why, but the disassembly-clean-assembly fixed the problem. I found some small alu flakes within the forks, maybe those were the cause.

Thanks for help,
Eskil

Duncan · Jan 4, 2010

Last year I bought a new KTM 300, forks didnt feel right, disassembled and found tiny chip of metal between 2 shims, reassembled and everything OK. A small chip can hold shim open and cause a major change in dampning. Makes me think there could be a lot of forks out there that need disassembly and cleaning. Glad you found your problem.

bushmechanic · Jan 5, 2010

doesn't take much

marchozzis on the KTM minis have their springs rubbing directly on the aluminium, 5 hours is long enough to fill the forks with shavings,

I just opened mine up 40 hours without a teardown thats a record :shock: , found bits of plastic from the spring spacers in one of the valves and loads of silt from the dust, should be a 20 hour min service for me.

swsupermoto · Jan 5, 2010

was the alu tube from the rebound adj in right, adds loads of rebound if its not

esvirta · Jan 5, 2010

I think it was. I reopened both forks when I noticed the uneven damping and checked alu tube movement and length.

Duncan · Jan 5, 2010

ya, when you thread the fork cap on the threaded tube be sure it bottoms out in the cap before it starts turning into the black plastic thingy with the aluminum nut on top. Otherwise you bottom against the nut prematurely thinking everything is OK but rebound adjustment is way off now. Usually if you keep your wrench in the aluminum nut holding down the spring it provides tension that pretty much ensures that threads bottom in fork cap first. Have I confused you now or what?

Different rebound on front fork legs?

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