Rebuilding forks - Gap between spacer

[Section59]

Alright people, hoping you can help me here.

Currently re-building my forks on my old heap of a TS200R and having an issue. Just put the forks back together (dry run atm, so i knew what i was doing, apparently i dont..) and there seems to be a gap at the top between the spacer and the spacer holder thingy (technical me or what!).

Once all together, you can lift up the forks a few mm with no resistance and they rattle a bit. Is this simply due to having no oil in them yet, or do i have a bigger issue here?

Don't want to put them back together only to find out i fucked something up and end up with no fork bottoms after a wheelie or something. Everything that came out, went back in, so no missing parts..

Any help appreciated!

[MickC]

Don'tknow myself but there is a parts fiche here if that helps:
https://www.bike-parts-suz.com/suzuki-recherche-bike-pieces_nn.php?compteur=2664&PartsListID=1516440
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[unitynotsocri...]

spacer,spacer holder thingy?do you mean the yokes(two of)that clamps the forks to the frame?If so then its usual for a small gap.Because the forks have no oil in them and are designed to work with the weight of rider/bike on them then they are usually always in compression.make sure the damper tubes inside the lower forks are bolted tight.If they still rattle when riding then check the headstock bearings and fork bushes.
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nearly a normal tax paying tosser.......with ferrileness suzi100,cg125,cb125scb100n,cb175,cd100,cj250t,kh250,c15,125 bantam,super 6,rickman gs750,xt500,250rs,dt175,lifan125,dolomite1850,metro,Morris220ld,morrisfg,leyland princess,range rover,corsa,vw camper .now struggling with legs. MORE ORDER = MORE CHAOS

[MickC]

nah he's on about the internal compnents of the forks (shows you in his pic)
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XX XXXx
Previous: CG125,XS250 (converted to 400),Z250A, GPZ550, Norton Commando, XS500, 78 Laverda Jota, GPZ1100,Harris bonneville, XV750 (mono shock),TR1

[unitynotsocri...]

Thanks MickC,am a bit visually challenged at mo,
on MickC's fork pikky it may be part 17 is missing.
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nearly a normal tax paying tosser.......with ferrileness suzi100,cg125,cb125scb100n,cb175,cd100,cj250t,kh250,c15,125 bantam,super 6,rickman gs750,xt500,250rs,dt175,lifan125,dolomite1850,metro,Morris220ld,morrisfg,leyland princess,range rover,corsa,vw camper .now struggling with legs. MORE ORDER = MORE CHAOS

[Teflon-Mike]

Normally there would be NO 'free' movement in a pair of forks, the spring would always be under some 'pre-load', ot when the suspension 'topped out' which it is actually more likely to do more often then bottoming out, load taken off the front wheel when it drops in a whole, or the front wheel is lifted, it would not have any reaction, and would 'slam' into the spring with a shock, when load came back on it.
If everything that came out has gone back in....
Check and double check everything is the right way round, normally springs, or the spacer on top of springs have to be pushed into teh stancion with teh fork cap before you can screw teh cap on.
If all IS as per the pic on teh microfishe or manual, check teh springs free length against specs... likely its buggered! They relax with age and hard work, and go short and feeble.
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