Speedometer Cable Too Tight

Did you actually remove the whole cable outer from the bike when you took the fork off? I just wondered if you might have got the cable mixed up with one off a different bike, if you had one laid about. Are you quite sure that the cable was of the correct length before dismantling?

Dunno how 15w fork oil would force the forks out farther, that doesn't make sense. I set the fork oil level at 155.5mm per the manual using this tool I cooked up:



I only disconnected the speedometer cable at the wheel while it was off. There's no chance the cable got mixed up.

The speedometer drive is in its slot in the forks:



I'm over-thinking something here, but I'm not sure what it is.

I don’t think there is anything wrong with the fork set up as the fork legs will only come so far out of the tubes if assembled correctly. If there was too much oil or air then that would just make them harder to compress. They would still extend to the same length regardless.

What does look suspicious is the way the speedo drive is located on the fork lug. I would take another look at this. Also the angle of the speedo cable doesn’t look right. In your video I notice the speedo cable is touching the bottom of the cable guide. Mine is touching the top of this bracket indicating the the speedo drive is further clockwise than mine.

You mentioned that the cable was OK before you took the front end apart... are you sure? If you have an aftermarket speedo cable in there - say a MotionPro - it wouldn't be that weird that the cable length is not right - I've had that happen with other MotionPro cables that I've used (or rather: tried to use).

Yes, my forks were/are 830mm from top to centre of the spindle hole. That is with the bike sitting on the centre stand and the front wheel off the ground.

Paul

For what it's worth, just went downstairs to take and post another photo. My both forks were totally serviced and set to proper setting by the manual. I connected the cable when the bike was sitting on both wheels.