SV Fork/damper rod problem
Alright this could potentially take more thought and technical knowledge than 99.9% of the questions posted by most people (myself included) in this tech forum, so get your thinking caps on:
The bike is a mostly stock '01 SVS. So I'm in the middle of putting new springs, oil, and emulators into my forks. One fork went with no issues and is back together awaiting the first test ride. The other fork is giving us some trouble. With no damper rod inside the tubes slide smoothly and easily just like they should, there is no sign of anything bent or out of place. Then when we put the damper rod and top-out spring in and get the bolt started into it the fork tubes won't slide apart. Thus the damper rod is catching on some internal fork part and we can't figure out how to get it to work. With the fork fully extended the damper rod is caught in the middle, but the working fork did the same thing and all we had to do was compress the tubes, get the bolt started into the damper rod and then extend the tubes. After trying a few times to get the problematic one to work we dumped the damper rod and top-out spring out of the fork, to our surprise a very small light-duty spring also fell out and it doesn't appear on any parts fiches or manuals...has anyone run into this problem? Any advice? I should have a picture of the small spring soon if anyone cares to see it.