A quickie rule of thumb that doesn't require you pulling the fork out to 
see where the threading ends:

1) Put the quill end of the stem up against the head tube/headset, with the 
lower end of the quill below the lower edge of the head tube/top tube join.

2) Put some masking tape/electricians tape around the quill at the point 
where the quill clears the headset locknut (or mark the quill with a 
sharpie, if you prefer).

That's your minimum insertion line.

In addition to Bill's reason, you're also trying to get the fork far enough 
down so that pulling up/pushing down on the bars doesn't crack the top tube 
join. The threaded section of the steerer tube is typically long enough to 
hold the top headset assembly, but not much longer; if you get down below 
the top tube, you're usually OK.

Peter Adler
forever fiddling with mis-sized threaded forks in
Berkeley, CA/USA

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