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Boxxer WC conversion problem with top-out. HELP !!!

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bushrider

Monkey
Jul 4, 2006
146
0
NYC
I'm having a intermittant problem with top-out on my 2005 Boxxer U turn upgraded to 2006 boxxer WC spec.
The problem is intermittant.

Initally when I upgraded the fork I had a top-out problem.
I reassembled the damper leg and the top-out went a away.
Riding yesterday the topout came back after a few runs.
Then later in the day the topout went away, then came back again ???

I'm pretty sure the problem is with the rebound damper.
Or maybe there is air getting trapped in the lowers ???
The lowers are 2005 non-maxle spec?

Converted my 2005 boxxer ride with the following:

06 Motion Control damper
06 Rebound damper
Honed stanchion tube
Solo Air Assembly
Solo Air top cap

The only parts that are not 2006/2007 boxxer WC spec are:

2005 boxxer crowns + steerer
2005 boxxer lower legs and axle
2005 boxxer right side stanchion tube (damper side)

Note:
I have tried running the solo air leg in a higher than the damper leg so that the topout bumpers on the Air spring side enage earlier. This does not help.
 
vitox

vitox

Turbo Monkey
Sep 23, 2001
2,936
1
Santiago du Chili
sounds like you have a problem with the rebound check valve.

what did you do when you disassembled the damper leg? did you check the rebound check valve spring? any deformity or dirt or improper positoning of that spring can mean that the check plate doesnt close the oil flow properly and the valve stay open also on the return stroke.
 
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