So i decided that I should take my RC40s apart and treat them to some new oil… should be easy, they're pretty simple as forks go really..

No probs taking apart , other than getting oil everywhere. Good clean-up rebuild starts fine right upto when I put the new oil in…. pump the forks to fill the damper with oil and as it does so it starts to hydraulic lock to the point where it wont extend past 1/4 travel. Its absolutely solid.

Ok so damper rod back out, take the top off and strip it, check all the holes are clear, no blockages, pumps ok, put it back in the fork leg put some more oil in…. Hydraulic lock again!!!

Anyone got any idea what I'm missing??? i'm only putting half oil quantity in to start the process….

Please help.
Thanks
JB

O dear looks like its back to the rigidness,sorry I am of no help!

Yep… sure does! Its got to be something daft!!!

Don't know anything about these forks, but have they got a lockout, and if so is it on? Had problems assembling a rock-shox fork because of this, could it be something similar?

Sounds obvious but you're sure the launch control isn't stuck on?

Can't think of anything else I'm afraid unless something has got in and is blocking the flow of oil through the ports in the piston.

One thing. How much oil are you loading it with? Overfilling will cause the problem you
mention.

Did you empty all of the oil from the damper? iirc there is loads of the stuff (it's been about 4 years since i had a pair so details are vague sorry)

Launch Control/Lock Out!!!! Of course!!!!! Doh…
Thanks Chaps.
JB