Rebound adjuster travel concern

I replaced the front fork oil in the 06 and 07 Ulys yesterday. The '07 appeared stock and doesn't look like it had been opened up in the past. The '06 has been opened up before as it contained the progressive springs like the '07 has. I can't tell if they're OEM or aftermarket.

I noticed the '07 (unopened) forks have about 2.75 turns on the rebound adjustment on top of the fork. That's from stop to stop. The '06 (which someone has been in before) only has about .75 turn from stop to stop. Perhaps when this fork was apart (for fork seals or something) it was put back together with incorrect damper locknut adjustment (per page 2-50 in the '07 manual)? The '06 rebound tube was also noticeably harder / slower to pump / purge oil from than the '07 unit.

I assume this will cause a lack of proper adjustment range until it's corrected. I've got replacement guides, bushings and seals for a fork rebuild. I had planned on doing that when I replaced the seals, but cleaning the seals using the "Seal Mate" tool fixed my leaky seal issue. Are there any other issues I should be concerned about with this? Would it warrant a tear down and rebuild I hadn't planned on doing just yet?

While the fork cap is off it is a good idea to check the range of the rebound screw and pre-load screw, in case theres burrs or galling happening.

Backing out the rebound screw will make installation easier and you must have the rebound adjustment backed all the way out before re-attaching the fork cap to the damper rod and setting the lock nut, or you will get the exact issue you describe.

Cooter said:

Backing out the rebound screw will make installation easier and you must have the rebound adjustment backed all the way out before re-attaching the fork cap to the damper rod and setting the lock nut, or you will get the exact issue you describe.

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This does not apply if you're just doing a fluid exchange, correct? Or even seals? The locknut adjustment only comes into play if the damper rod has been disassembled, correct?

Since both legs have exactly the same .75 turns of adjustment, I think someone put took them apart and re-assembled them precisely, but incorrectly.

If I have forks apart, they go all the way apart and back together correctly. I've seen enough, that I have trust issues with the 'last guy'.

I learned it the hard way. Just did fork seals twice in one week. But it’s worth it once you start riding it and forgot how good the suspension is.