Damping rod breakage

[honda65]

I have a 2021 300 One RE and the other day I decided to check the oil level in my forks. Did the spring side no issue. When I pulled apart the damper side I discovered that the cartridge rod was snapped off right below the cap. I seem to vaguely rmember hearing a pop a couple of days earlier while riding and that it was steering weird, thus my wanting to check the level.

Has anyone else have this problem? Did I over-tighten it? I have worked on well over 10,000 forks in my life without doing anything like that but anything is possible I guess. The only other variable is that I added a longer preload spacer on the other fork because it still sagged when cranked in all the way. But I have been riding it with the new spacer for months.

Lastly, anyone happen to have a internal damper for late model aluminum Tech forks laying around? I have calls in to TRS and also inquiring with Gas Gas and Vertigo dealers to see who has what and prices. Gas Gas version in only $160 but seems like it might take a long time to get. I would be happy with a used one.

[konrad]

Interesting problem.

The first search result for the GG P/N says it ships in 2-5 business days: https://www.ocpoemparts.com/oemparts/p/gasgas/bt20220gg-cka-1/cartridge

I find it difficult to imagine a guy who's done 10k forks over-tightened it.

How much longer did you make the preload spacer? But even if the spring went into coilbind, I can't see that breaking the damper rod. 

Can you post a high-resolution photo of the break?

Edited Monday at 02:25 PM by konrad

[honda65]

Hey Konrad, thanks for the link. I checked a couple of others and it was longer. I also have a message into TRS (Rising Sun Imports) and hopefully he will have one in inventory.

I thought about the coil binding possibility but I came to the same conclusion as you. I don't remember offhand how long the spacers is total or how much longer but it wasn't radical.

When I get home I will take a pic.