PLEASE HELP with finished 05 fork convesion!
 

Hello,

I am a long time lurker and this is my first official post. I have been searching and searching this forum and google. I have an 2004 RR and I put a 2005 front end on the bike. We put brand new race, bearings and every single piece inside the frame. I mean everything is OEM honda new. I own a small shop and purchased all internals for both 2004 and 2005 even though they shared the same part number on some items like dust seals and such. The front end has play in the forks like the top bearings are sliding out of place. If i tighten any tighter i believe i will crush the metal ring that holds all the seals in. In the past I have put 954 front ends on 600f4i's and for some reason I can not figure this out!! I have a video showing the crazy play, just uploaded via iPhone. Every time I hit the breaks the whole front end shifts forward. I need to know how to remove the play in the forks, any ideas!?

Thanks in advance,

Fork Play Video Link


http://i62.tinypic.com/abmtlc.jpg

Ahhhh any one have any tips, or can point me in the right direction for some help!?

The races are clean and clear of metal shavings. I can not seem to get the bottom race and bearing to move down enough to let the top get in the proper position. The top spacers on the stem is just not in the correct position in the steering stem channel for the bearing to sit properly.