40rc2 Problem

[FR4life]

So, my 40 makes this clicking noise when it is compressed to about 3-4". this noise occurs at the same point, every time compressed. Also, it makes a rattling noise as if something inside the fork may be loose or worn out. Normally I do all my bike maintenence myself and have rebuilt a boxxer fork before, but I don't really know that much about fork internals and rebuilding them. In this case I would like to be able to fix it myself but I'm pretty paranoid about doing it the wrong way, and would rather have it rebuilt by someone who has done it before and knows what they are doing. Has anyone had a similar problem before? Should I just sent it in for a rebuild? Could this be really expensive to fix:06:

-Chris

[BighitZ]

Mine did the exact same thing when I got it. It may be a very easy fix (mine was) The left leg is the spring side and is very simple. Take the top cap off and slide the spring out (there may be up to 4 travel adjust spacers on top). Make sure the black sleeve is in the middle of the spring, it is to keep the spring from hitting the stanchion wall and making a clicking noise. Also it may take a few tries to seat the spring properly I had to take it apart a few times to fix the click.

Also the whole fork is fairly easy to rebuild, even the cart. The manual is on the fox site http://service.foxracingshox.com/consumers/index.htm

Good Luck.
-Zach

[Sirbikesalot]

Yep, BighitZ got it right. The spring is hitting the inside of the lowers. What bike are you riding these days Chris?

[FR4life]

Originally Posted by Sirbikesalot

Yep, BighitZ got it right. The spring is hitting the inside of the lowers. What bike are you riding these days Chris?

I just got a demo 8. It's an 06, completely stock. It's a dope bike, so much faster and stiffer than my bigsh1t.

[FR4life]

As of now, I just finished shrink wrapping the spring. With the wrap in the middle as recommended it definately muffles the rattle, but it is far from gone. I tried various other placements of shrink wrap on the spring as well, and so far have had no luck eliminating the rattle... :sigh: What would be the best thing to try at this point?

[FR4life]

Put on a second layer of the shrink tubing, and now I can ride over bumps in peace and tranquility! :01:

[Chase91]

nice dude pretty satisfying when u fix a problem like that haha