I've just replaced the seals in my front forks on a TTR 250 Raid.
When re-assembling, the instructions are to use 550mm of oil then adjust the level to 130mm from the top of the inner fork tube (fully compressed). However, it then took another 40mm of oil to reach this level - total 590mm. Is this because the raid forks are a bit different to the standard TTR - the damper rod (item 1 in the attached image) is not on the raid forks. Maybe the extra oil is taking up the space where this would normally be. it's just that I haven't seen anywhere where it says the amount of oil to use is different for the raid.
Any advice would be appreciated, just in case I have made a major ****up.
I think your theory is probably correct in explaining why Raid forks need the extra oil to reach the 130mm mark.
In all my time working with TTRs, I have not found a workshop manual for the Raid so have not been able to check my fork rebuild instructions for the Raid model.
If anyone reading this knows of such a manual, or indeed the volume of oil recommended, then please let us know and I will update the rebuild instructions
I think you have done the right thing in matching the 130mm measurement. Also, I cannot think of anything untoward that might happen if by any chance it isn't 100% right!
The guy who does my suspension used to do ballards bikes swears by raising the level by ten mm really reduces the dive .he also said there is no way to over fill them (I haven't put it to the test )