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I bought what appears to be a low hour, neglected '05 200. Still had the original front tyre, which was in good shape.
I have been systematically tearing it down and replacing worn out, rusty parts.
Been fighting me the whole way, but not too bad.

Did a simple fork oil change today.
Followed the Service Manual, the OEM Manual, and the Tech Spark studio CD instructions.
I do not know if the sound was there before I swapped out the fluid, but now I am getting what I can only describe as A noise resonating from the spring when I compress the right fork leg. It almost a clicking noise coming from the bottom of the fork leg.

Don't know what details can help diagnose the problem, even if it is a problem. Just know the left leg does not make a peep when I compress it.
The forks were removed from the bike for the fluid change.
I have all the necessary tools. Spring holder, damping rod puller, Motion Pro fluid gauge.
I measured the springs, they were is spec, I added Bel Ray 5wt to 90mm(~530ml-ratio rite cup measured)
I even pulled the spring and rechecked the fluid level and reassembled the fork twice.

I would say I am average wrench,. no expert mechanic, and this seems like a very simple job.
Just FYI, I have already dumped a about $1000.00, maybe more in nice upgrades so suspension mods were not on the table right now.
And, from what I have read, at 150#, the stock suspension should serve me well for now.
Open to suggestion though, but $ is a little tight right now.
Thanks

Look up fork click in old threads. It has come up several times. I think it is fairly normal. Did you still have the stock special washer connected on the bottom of the fork spring?

Some stiffer fork springs would help in the future when it meets the budget.

KDXGarage wrote: 07:13 pm Feb 21 2022 Look up fork click in old threads. It has come up several times. I think it is fairly normal. Did you still have the stock special washer connected on the bottom of the fork spring?

Some stiffer fork springs would help in the future when it meets the budget.

Yes Sir, I did have all the washers installed and properly orientated. One manual says the spring orientation is not important, but what I saw was a clear difference between the ens of the spring. I just made note of which end was which when I pulled them, and put them back the same way.
I did try looking up and old thread on fluid replacement etc, but I could not find anything relevant, sorry.
I cant tell if the noise is coming from the valving or the spring. But yes, it almost sounds like the spring is catching on the preload spacer.

As far as the upgrades, the list I have done is fairly extensive now. All my buddies are on the latest and greatest two strokers and I want one up them with this iconic and competitive old girl.
I will be upgrading the suspension with Gold Valves and springs at some point.
I just did not want damage anything if I could fix this.
Thanks

Do you have a washer between the spring and the preload spacer?

Are they the stock springs?

Several people have heard a click when compressing the fork after reassembly.

I would not worry a lot about a Gold Valve in the rear, as the stock piston can be made to work well with some shim changes to suit each rider.

Proper spring rates and fresh fluid go a LOOOONG way toward making it work better.

Tighten the top cap by holding the cap and turning the tube. That will eliminate spring torsion that can cause some clicking noise after you get it back together.

Found it!

"Do you have a washer between the spring and the preload spacer?"
Yes, washer, spacer, washer. And washer orientation installed correctly.

The springs measured at 469mm. Service limit is 448mm.

"Proper spring rates and fresh fluid go a LOOOONG way toward making it work better."
AGREED!
Good brakes and properly set up suspension will make you faster and the bike more of pleasure to ride.
That could be said about any vehicle. Best start to a build IMO. Then you can begin with the power.

First step: NEW PLASTIC!!
Second step: SHINY PIPE!!
Third step: uhhh, other stuff I guess

So I bring my forks to my local suspension expert, and, my forks make a liar outta me.
The sound is longer there...so I'll bolt em up and get ready for spring riding!

They will click as soon as you get them mounted. :-)

Stay safe out there, and have fun.