Subject:RE: Front Forks Date:Sat Mar 7 06:20:20 2015
Response to:5546

I've got a strange problem that I want to run by the group
here to see what the experts think.
The front fork of Chris's KJ were making some noise and he
was told the damping spring will break and cause some
noise issues. I pulled the for apart this afternoon and
found the cylinder that houses the damping spring is
striking the steering head in two spots on compression.

My initial thought is that something is bent and although
the main fork tubes are tapered everything appears to be
good. At some point I noticed the yoke at the top of the
damping rod that attaches to the stem on the handlebar
center was ground to provide clearance.

The photo is of the backside of the front section and you
can see where it was hitting and the clearance yoke.

After thinking about it I feel the most likely scenario is
the handlebar got replaced at some point with one that had
a different gooseneck stem locating the top of the damping
rod. Were there variations on that? If this one is higher
and not as long it would explain all the trouble.

Now the stupid question. When I go to reassemble the fork,
what is the trick to compressing all the springs at once?