are the small square pivot bearings that fit between fork and bearing free and not siezed, also is crank endfloat ok and not excessive? is it a new fork that you fitted [modified type with strenghened plate welded over pivot point], you could try removing pivot post and put flat washer/s on it which would take piston further down cylinder and less liable to pop out! dont over do it though.
k
September 2008
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