Is it possible that one fork is taller than the other? - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 14 Old 03-04-2014, 03:20 PM Thread Starter
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Is it possible that one fork is taller than the other?

So I have rebuilt my forks with Race Tech Gold Valve Emulators and new springs and went to reinstall on my bike and one fork is taller than the other. I cant see how this can be. I don't remember one fork being higher than the other in triple clamp but that is the only way I can see how this will go back together... What am I doing wrong. There is no way to put the axle through with 1/2" difference... Here are a few pics to show what I am dealing with..
The funny thing is the fork that has the Taller fork Lower is the Shorter one overall..



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post #2 of 14 Old 03-04-2014, 03:29 PM
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Do the axles line up? That's all that matters.

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post #3 of 14 Old 03-04-2014, 03:31 PM Thread Starter
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Do the axles line up? That's all that matters.

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Not unless I put one higher in the triple than the other. Is this right?
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post #4 of 14 Old 03-04-2014, 03:39 PM
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Did you leave the top out spring out of one of them?
Also, on some bikes, like the 2nd gen SV, one fork leg is "deeper" below the axle. So if you just stand the legs up together that one will be longer. But the distance from the axle center line to the top is the same. Can't remember if the Strom is like this or not.

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Last edited by RichDesmond; 03-04-2014 at 03:42 PM.
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post #5 of 14 Old 03-04-2014, 03:39 PM
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When the axles line up, the tops should also line up. Something is wrong but I couldn't tell you exactly what. I don't know for sure if both fork tubes are the same. PM Rich Desmond.

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post #6 of 14 Old 03-04-2014, 04:09 PM
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Doesn't seem quite right to me, but I'm not an expert on DL forks........ on the parts diagram everything is twins except the fork lowers. If you put the axle in both, then your tops (dust seals) should line up, but if your picture is correct, that would make your difference at the top worse..... so, next I would remove the top caps, springs and spacers to ensure they are the same length. While out, slide the inner tube down and back up until it hits a stop. Mainly you're trying to see what's different between the two if the tubes won't come up to equal height.... making assumptions that all is assembled correctly at the bottom, no missing parts or rebound springs, and that the damper rod and oil lock are properly together, both screws at the bottom went in the same amount, etc.
Slowly pump the fork tubes up and down in case there is trapped air (I am not sure what the gold valves will trap, nor if a hydraulic lock can even occur with them). I don't know how the gold valves go in these forks, but can you check if they are seated?
Hopefully you can figure it out at this point, as the tubes should be the same height I would think. IF they are now, put the springs, spacers and caps back on.......
You might need a helper to look at both forks at once, be aware of the oil level when moving the fork tubes up and down.........

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post #7 of 14 Old 03-04-2014, 04:18 PM
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The right lower tube extends down farther to give room for the pinch bolt. Everything else should line up---top of the uppers, dust seals, axle holes. If they don't, you've mis-installed something.

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post #8 of 14 Old 03-04-2014, 04:23 PM Thread Starter
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Thanks for your help. I'm gonna pull them apart once again and make sure everything is installed properly. Should have taken this to a shop in the first place... What a PITA...
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post #9 of 14 Old 03-04-2014, 04:39 PM
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Quote:
Originally Posted by lacofdfireman View Post
Thanks for your help. I'm gonna pull them apart once again and make sure everything is installed properly. Should have taken this to a shop in the first place... What a PITA...
Really looks to me like the longer one (the one with more exposed tube) is missing the top out spring. Either that or the bushing and seal aren't seated.

You can test for the top out springs by trying to manually extend the fork. You should be able to pull it apart 6-7mm or so. If there's no give at all the top out spring is probably not there. Compare both legs, see if they feel different when you do that.
For the seal/bushing, pry the dust seal up and make sure the lock wire is seated in it's groove.
Either way, I'll bet the issue is with the longer fork leg.

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post #10 of 14 Old 03-04-2014, 05:20 PM
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Could you have somehow trapped air in the fork somehow - perhaps when you were refilling the fork with oil, you didn't cycle the fork thru it's range a few times, to drive out any trapped air in the damper rods, before putting the caps on?

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