@Knackers let's do this right. Set your bike sag to 25-30 mm front and 10-15 mm rear; your rider sag to 40 mm front and 30 mm rear. I will measure a set of set of oem Showa forks and let you know where the bottom is then you can take a Sharpie and mark your fork accordingly and then use a fork travel indicator to see how close you are to the actual bottom of the stroke. I am pretty sure you are bottoming out your forks as you are at the top of the weight for stock springs.
Some of your settings that you shared need some explanation....also please list the stock settings in your manual for reference in your response.
Front:
Ten - 4 out from fully closed
Com - 5 out from fully closed
Pre - 6 turns from fully open
<-- you probably need more but let's get that sag set properly.
Rear:
Rebound - 16 out
Com - 1.5 out from fully closed
Preload - 14mm
<-- how did you measure this? I measured it from the exposed threads to the locking ring nut
AFTER proper sag is set, what I like to do is set fork rebound. First remove all compression at both ends! I am looking for the fork to return from a firm push with the front brake on and return to the original position without bouncing more than once.
If the fork bounces like an old Cadillac with a hoping well slow the rebound down (turn clockwise) and do the opposite if it doesn't return to its original position. The fork can come up and then settle but you don't want it to not return all the way or be slow to return. I prefer to leave the "clickers" as open as possible .... none of this "I am a fast guy so I gotta turn it in" kinda stuff, ok? You would be surprised at the number of people that do this and wonder why the bike doesn't work anymore.
A good test to see if rebound is too open is the fork will pop up between gear shifts on track. After the fork rebound is set next move to the rear rebound and match the rate at which the front returns with a similar input into the shock. Developing this feeling takes time as you want to be able to push through the center of the bike to get it to compress the front and rear at the same time and ideally return at the same time. A second person standing to the side of the bike helps OR you can take two laser pointers and attach them to the bike pointing at the wall and observe this yourself - it works, ask me how I know?
Once you have rear rebound set so that the front and rear of the bike are in balance you move to compression and I go first to the fork then repeat the same process for like rates, however, I like to think of rebound like it is a fact and compression is more of an opinion. Depending on your environment (street or track), pace, spring and preload, and surface conditions the compression settings will vary. I would start with oem settings and confirm if the bike first steers without fighting you on entry, next does the bike run wide on exit? If both of these aspects of the bike are good then your geometry is probably good but if you have changed gearing, tires, tire sizes, your chain isn't properly set to correct tension, etc, these can and do cause havoc especially when tuning remotely over the internet. Oh and relatively NEW tires set to proper inflation for the environment in which they are used helps a lot in getting a setup that works well.
Let me tell you a quick story....recently I had a customer who started tinkering with a bike I built him - he got faster and faster and started changing things and didn't tell me until he had a problem so, of course I am happy to help him so I tried to understand his new issue. He decided to change the rear shock spring up TWO rates because he saw another friend with a similar bike who was faster and he thought this would help. So I started from the beginning to decipher what he had done. He swore to me he had properly set sag but he only had 5 mm of bike sag from the rear shock and 30 mm of rider sag. I spent 3 hours on the phone trying to help this guy and asked him several times about exactly what he did. After all this time I had him send me a video of how he set the rear sag....EXACTLY how he took measurements.....well he never actually suspended the rear of the bike on the peg stands to take the first measurement so everything was off. DETAILs matter. When I set sag I take FIVE measurements from each end and average them to account for fork seal stiction and linkage stiction AFTER I lubricate the linkage and set the correct torque for the shock, linkage and triple clamps.
None of this stuff is rocket science but it does take time and attention to detail to do properly.
Maybe I will do a video on how I feel is proper way to set sag ...