Forks rebuild Issue.

[drbaig]

So I bought a stanchion and it got delivered yesterday from germany so I thought lets do the rebuild. Come across a major issue or minor but I don't know so asking for help.

The bottom of the fork stanchions are different.

The one on the right is from the bike (original) and the one on the left is the one I bought.

https://i62.tinypic.com/or16he.jpg

Also there is a few parts that came out of the stanchions.

https://i58.tinypic.com/95y59i.jpg
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yzf 600r

[sickpup]

Did your original have bits held in the bottom by that big snap ring?

[drbaig]

Yes. in the order of 1 4 3 2 of the second picture the above post. The picture shows the part 1 and 2 already in the left fork tube.

https://i57.tinypic.com/11jxjc0.jpg

I came to the conclusion that maybe I don't need that slide metal inside the fork stanchion and the clip at the bottom. The oil lock piece/damper rod seat fits at the bottom of the fork. But then it sits a few mm higher like this. Left the one I bought, right OEM.

https://i58.tinypic.com/op4nl2.jpg

Then I also checked that the damper rod assembly sits a few mm lower in the fork stanchion.

https://i59.tinypic.com/2vngz6c.jpg

I am thinking that the fork tube is not for a thundercat and maybe some other bike ?

Or maybe it is not an original tube and a pattern one. I am completely baffled by this. I think the tube is going back to the seller and I will have to try and source an OEM new one from somewhere.
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yzf 600r

[sickpup]

Now I could be wrong but I believe the fork you had, the one with the circlip is actually an ABE fork not a genuine. These use the shuttle from the original fork which is held in place on the original with a peened over end, like your new fork but with a circlip on your old fork.
The chrome tends to be slightly duller on ABE forks as well if that helps.

[drbaig]

Fuck me sideways if that is true. So the forks I have are not original. Well done.

The finish on the forks is slightly dull on mine. The one I bought is shinier.

So What about the few (3mm) difference that I am encountering. Can I use the ones I bought with the ones I have or do I have to buy another to make sure they both are they same.
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yzf 600r

[sickpup]

3mm difference in length shouldn't make any difference, after all the forks hang on the springs.

[drbaig]

Yeah I was trying to figure out mentally that the damper rod is fastened to the fork cylinder at the bottom, the stanchion to the top cap at the top so they are not exactly bottomed out.

What I was wondering was how that would effect the damping rod for rebound damping.

I am tempted to just do it and see how it goes and if there are issues with handling to get another stanchion to get both back to oem.

Also the next job is going to be head bearings. Already dreading it.
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yzf 600r