just about the same machine as mine (FE400e - '02 model) i found the suspension to be a little 'spiky', i pulled the middle compression shim out (the 18mm shim in the forks) and this helped but in the end i took front and rear in to K-tech here in the UK.
they found both sets of bushes shagged and the non-slip material was clogged with swarf. the stop rings were buckled and they even found kinked shims in the stack. the fork seals were changed for better non-leak types, threads cleaned and forks filed to get rid of stone chips. truly a work of art IMHO.
although i said that the sussies were wrong they built them with all new kit and even put the 18mm shim back in, citing the shocking condition as all that needed sorting. i think they copied the '03 KTM settings. they were slightly better.
i sent both back and said what was wrong STILL and always had been. spiky on the front with the comp screws right out and rebound screws being irrelevant. on the back on a rollover hill i would get launched due to a lack of rebound control.
both were sorted on returning them to the shop. the shocks are now awesome, so much so that because both ends are collectively better, i have now taken three clicks off both ends as the whole ship is so stable.
the '03s have 3-bush forks and a larger wheel spindle making the front end far more rigid.
what i'm saying is that your forks will be truly knackered by now and a rebuild with mods is due. i think the sussie boys will simply take the settings from the '04 bikes and copy them unless you have a unique set of changes that you want doing.
i think it's money very well spent. suspensuion is everything.
Taffy
