ok so you have the notorius Hydra clunk, well this a somtimes mystery that cant be solved with some hydra glides, first yes manual break down and parts for your internals are correct for your year, you can do some parts changing and still end up with the same issue, Your best bet as far as bettering your chance to rectifying the mysterious clunk is to start with new fork tubes,but you might not want to due that, but I would at least do new springs my choice progressive ,dampers my choice race tech gold valve dampers.do away with the original style seals with the felt wiper and do the upgrade seals, there is a lot of mystery behind this clunk some feel its the bottle cap stak dampers some feel it has to do with the 1/4 hole in the damper tube bottom that creates issues with how fast or restricts the fluid flow . if I remember correctly there should be 0.0004 free play from the snap ring and lower bushing , 6.5 oz wet 7.0 oz dry as far as fluid capacity. all I can say is my past experiences wth the clunk has been the above upgrade has corrected this issue, I have learned when it come to the clunk my best results came from changing everything all at once ,trying to isolate the problem has never Panned out for me, excuse the pun , Im sure you will get many opinions on the clunk ,but I think the problem is never just one part . as far as fluid to much will blow the seal to little will be to soft, heavy weight fluid will not fix the clunk you have.another couple of things if the parts are found to be aftermarket make sure that 1/4 '' hole in the bottom of the damper tube is 1/4 '' some after market parts were larger and caused this issue also check the snap ring for proper fit some after market snap rings did not fit correctly and left the free play clearence on the + side f the specs. good luck with your Pan .
