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Discussion Starter · #1 ·
Can anyone help shed light on this?

I bought a set of fork internals in the hope i could pinch the tops and replace my tatty ones however the damper rods have different threads? so i cant use the new ones i bought to replace tatty ones without changing over all the internals (and i believe my existing kit has a k tech piston due to purple adjuster at base of fork and the fact the fork feel ace at the track with my 110kg on board)

My existing forks are off an 04 and have no bump stop on the damper rod

the set of internals i bought have a larger thread and a bump stop fitted maybe half way down the damper rod?

Have only ever swopped oil and seals before so this is beyong me and frusting to death, any help mush appreciated
 

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Are the cartridge tubes larger? All of the 04-06 stuff I've worked on has been identical. The 07-08 had 24mm cartridges and were overall larger in diameter both at the cartridge and rod. So those caps won't fit.

Do you have pics?
 

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Discussion Starter · #3 · (Edited)
Here you go not the best but a clear mm or two different guessing like 10mm on existing thread versus 12mm on the ones i bought?

the main body of what i assume is the cartridge is 28mm diameter on the ones i have been sent i am unable to check mine as still in forks after fitted new seals and topping up only to come to find the above issue when attempting screw tops on
 

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Definitely appears to be 07-08 cartridges.

Do you have two complete cartridges/caps from the stuff you bought?
 

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Discussion Starter · #5 ·
Right make sense I measured bought parts at 28mm and mine now removed are 24mm am guessing bump is removed as part of revalving? I also have 9.5 springs in mine.

Is the 07-08 stuff usable? Or am I better sending back and keeping mine with the uprated internals?

Oh and cheers for your help pal
 

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Check the lengths of the two cartridges. If they are identical, use the 07-08 stuff. It's improved. The 07-08 springs were in the .95 kg/mm range also, so builder's choice on the springs.

If the lengths are slightly different they can still be usable, but may need some adjusting.

No worries on the help. I'm a little familiar with this stuff :thumbup
 

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Discussion Starter · #7 · (Edited)
Ok so not a total loss, the cartridges are identical length, the 07-08 springs are ten mm shorter than my current 9.5s they look OE but aren't marked up so would rather stick to the ones I have been using

My original forks felt ace and I have been told they have a k-tech piston kit fitted - would this not be superior to the OE 07-08 stuff, can I safely separate the cartridge to check or is this a massive pita?

Also Is the red comp adjuster just a gimmicky bit or is it designed to specifically work alongside the piston kit? And therefore is it usable if I use the 07-08 cartridges?

Cheers again
 

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Ok so not a total loss, the cartridges are identical length, the 07-08 springs are ten mm shorter than my current 9.5s they look OE but aren't marked up so would rather stick to the ones I have been using

My original forks felt ace and I have been told they have a k-tech piston kit fitted - would this not be superior to the OE 07-08 stuff, can I safely separate the cartridge to check or is this a massive pita?

Also Is the red comp adjuster just a gimmicky bit or is it designed to specifically work alongside the piston kit? And therefore is it usable if I use the 07-08 cartridges?

Cheers again
Good deal on the length. I've got both cartridges and I'm looking forward to putting a set of 07 cartridges in my 04 forks, with Race Tech valves.

The 20mm K Tech may or may not perform on par with the 24mm 07 cartridge. If the K Tech stuff was setup specifically for you. If not, the 24mm stuff will probably perform better because of the size and the fact there is a mid valve built it.

The service manual states the 04-06 springs should have a free length of 236.5mm and the 07-08 should have a free length of 237.5mm. So close enough that they would be interchangeable with the respective spacers, resulting in between 10 and 12mm of preload.
 

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Discussion Starter · #9 · (Edited)
Ok sounds good, just t clarify I have been quoting externals diameters, am assuming you are quoting internal?

The k-tech springs from my 04s are 10mm or so shorter than 07-08 OE ones is this down to spring being stiffer? All spacers etc are identical

Ps if I am to utilise this 07-08 stuff and get on ok, can I confirm there are k-tech internals in my old stuff simply by undoing the base of the damper and sliding it all out? Seems like a good opportunity to familiarise as they won't be used for owt else?
 

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Ok sounds good, just t clarify I have been quoting externals diameters, am assuming you are quoting internal?

The k-tech springs from my 04s are 10mm or so shorter than 07-08 OE ones is this down to spring being stiffer? All spacers etc are identical

Ps if I am to utilise this 07-08 stuff and get on ok, can I confirm there are k-tech internals in my old stuff simply by undoing the base of the damper and sliding it all out? Seems like a good opportunity to familiarise as they won't be used for owt else?
Yes, I've been stating piston sizes.

If the spacers are the same length you want to use the ones that will give you a set length (installed length) of 10-12 mm less than the free length of the spring.

You may be able to identify the pistons used, but it would require full dis assembly of the cartridge. Taking the bottom off the cartridge will not allow the internals to come out, but you would remove the compression piston (rebound is mounted on the rod, which will remain in the cartridge).
 
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