Hi, I have just rebuilt my forks and filled with 450cc of 10wt oil as I believe is correct from reading existing posts, however when I check the fork oil height, it is no-where near the 90mm I was expecting (again from reading earlier posts). Question is, do I stick with an accurate measure of 450 per leg, using a measuring cylinder, or do I top them up and set level to 90mm? All internals are stock early type btw. Thanks.

Oil height was measured how?

Forks fully compressed. (All air pumped out). No springs, spacers or washers in tubes, measured down from top face of stanchion to surface of oil using a vernier. I also have a syringe set up at 90mm but that obviously does not touch the oil at the moment! Thanks, D.

They are damper rod forks ie no external adjustments?

I had the same on my rvf forks - I just set it to the air gap.

Magg, they are early type with nothing but pre-load adjustment - excuse name change-forum issues!

450cc/90mm are haynes numbers for the early damper rod fork, not sure why the volume/height numbers do not match. Having said that, I use the air gap number when refilling my late model forks, so maybe the volume/height numbers also do not match. Suzuki416 experience suggests that none of the numbers match. As the air gap is what matters, provided the oil covers the damper rod on full extension, I would suggest you use the 90mm height. How the forks react when approaching full compression and their resistance to bottoming is controlled by the air gap and can thus be adjusted for rider preference if necessary.

Thanks Magg & Suzuki,I will set to 90mm