Forks aren't so smooth after rebuild

[ophic]

Just replaced my fork seals. Went for a slightly lighter weight oil than the 15w i had in before. (and it was purple!)

Now it's all back together, there's a minor "clonk" when bouncing the front end, and a fair bit of stiction. Is this normal? I don't remember it doing this before - although i didn't waste time bouncing the front end much with the engine off, admittedly. Without the internals fitted, the forks felt quite smooth.

The only bit that went wrong was refitting the front wheel. Pig of a job getting the axle to engage the threads. I eventually loosened the right fork and managed, but it was very stiff. I've probably cross threaded it. GSXR front end time?

[TamSV]

I remember much the same with my RGV. Ended up taking it apart and doing it again and all was well. Whatever I'd cocked up was de-cocked. Just a wee alignment mishap probably.

[ophic]

Originally Posted by TamSV

I remember much the same with my RGV. Ended up taking it apart and doing it again and all was well. Whatever I'd cocked up was de-cocked. Just a wee alignment mishap probably.

Yeah i found your thread. I don't think it's alignment as I've already had one fork completely loose with the wheel fitted.

I spose what I'm after is for someone to bounce their SV and see if it's completely smooth throughout its travel or does it clunk slightly. Plenty of threads across the internet about clunky forks after rebuild, but the common theme is none of us muppets know if it did it before.

[johnnyrod]

The forks can go out of parallel if you've had them off. Leave the bottom yoke alone, slacken the top yoke pinch bolts a little, and also the pinch bolts for the wheel spindle (not the main nut). Bounce the forks a few times and re-tighten. This won't change the alignment but will get them running parallel to each other again, and you should feel a difference.

[ophic]

Originally Posted by johnnyrod

The forks can go out of parallel if you've had them off. Leave the bottom yoke alone, slacken the top yoke pinch bolts a little, and also the pinch bolts for the wheel spindle (not the main nut). Bounce the forks a few times and re-tighten. This won't change the alignment but will get them running parallel to each other again, and you should feel a difference.

I've done all that, and a few other things.

Am I to assume then that a slight clunk definitely isn't normal on stock SV forks? Does anyone even still have stock forks on their SV?

[Bibio]

i'll hazard a guess and say that one of your damper rods is not sitting in the stanchion properly. did you look down the stanchion to make sure that the damper rods were sitting in the middle of the stanchions when you put the forks back together.

or one of your fork legs is bent.

[ophic]

Originally Posted by Bibio

i'll hazard a guess and say that one of your damper rods is not sitting in the stanchion properly. did you look down the stanchion to make sure that the damper rods were sitting in the middle of the stanchions when you put the forks back together.

or one of your fork legs is bent.

Hmm not sure how that can happen. Isn't the top of the damper rod the same diameter as the inside of the stanchion? and the other end is attached to the bolt.

I had some trouble getting the cup thing aligned properly - "oil lock" in the diagrams - but i'm pretty sure i managed to get it right eventually. It can only go either right or upside down.

I need some time and daylight to look at it properly, but I think it's either:

a) they all do that sir
b) play in the disk mount - semi floating brake disk
c) worn bushes

the added "stiction" is probably just down to the new seals.

It could just be me being paranoid. I haven't managed to get it out for a proper test ride yet so I can't tell if the handling is affected.

[Bibio]

yes but the damper can sit squint, i have been there.

if your using the standard springs than yes you do get a clonk now and again.

did you pump the stanchions up and down to dispel the air when you put the oil in before measuring the oil height?

[ophic]

Originally Posted by Bibio

yes but the damper can sit squint, i have been there.

if your using the standard springs than yes you do get a clonk now and again.

did you pump the stanchions up and down to dispel the air when you put the oil in before measuring the oil height?

Yes pumped the stanchions, I'm sure there's no issue with oil level.

I'm not talking about the SV fork clonk when you hit a big bump. It's totally reproducible just by bouncing the front end.

[ophic]

Originally Posted by ophic

I need some time and daylight to look at it properly, but I think it's either:

a) they all do that sir
b) play in the disk mount - semi floating brake disk
c) worn bushes

I'm such a dweeb sometimes. It was b)

Thanks all for the input.

*Sigh of relief* If I'd broken my bike, I'd have to ride Miss Ophic's cruiser to work...