From:Rick Yamane e-mail:rick@motionpro.com
Subject:Front Forks Date:Thu Mar 5 18:39:34 2015
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?

Thanks,
Rick