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Sounds about right. The fit is very close if not tight, but it is do-able. So far Ive only been able to reliably get the AAS struts to work with the 2nd gen konis.
How far down does the insert get? If it gets about 2/3-3/4ths of the way down it bay be getting hung up on the welds made for the brake line bracket. You will have to file that down to get the insert all the way in.
Another thing is the base of the inserts themselves. I have had one set of konis where the welds for the base was very, er...robust. It actually protruded beyond the overall width of the insert tube. I had to shave that down as well to have the insert get into the donor tube.
Finally....I havent had this happen to me or anyone else who has done this (but it is a possibility) but with the AAS struts we are dealing with some loose tollerances of the outer tubes since all the action happens in the inner tube(twin tube struts). It could be that that set of AAS struts was made just a bit too narrow on the outside and, well ...there you are.
Good luck. Check the other stuff first.
Gavin
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