Help with Fork Reassembly

OK, waiting on an order from Chacal to get these forks done.

Got mildly impatiant while dissasymbling the left fork and have a couple of parts that have NO HOME. I think they are parts from the dampner rod, but not 100% sure.
Got right fork without the spring and circlips attached, but still waiting so I can focus on where this and that go.
There is a cone like thing and two skinny washers that are in question on where they go!

Also is there a specific procedure in which the oil seal is seated?
If you can go in baby steps I would appreciate very much(prob some lurkers too)

Any other cautions will be noted as this has never been completed by myself before.

 

Here's some photo's I took of a set of 900 forks that may or may not be of use

XJ900 Fork Pics

 

This project is coming up on my to-do list. Chacal has supplied me with the special tool for getting at that hex bolt down inside, so the only thing holding me back is ambition and weather. I'm also planning on another How-To for this project.

 

Can't comment on the washers since I have a 750K maxim but the cone shaped piece goes on the end of the damper rod.
Basic procedure to seat the seals is to clean the seal seat first and do so very well. Lube the seat with some fresh fork oil and use a large socket that just fits inside the outer lip of the fork leg. Seal goes in first followed by the washer, circlip and finally the dust cap.

 

The very best thing to do is to Jack the Bike and patiently disassemble the opposite fork ... taking pictures, making notes and / or drawings of where those parts fit because its unclear in your write-up what they are and where they might go.

If I had to guess ... I'd say you have the thin wave washer and the thin flat washer that is the end-stops for the Oil Lock Piece.

The Oil Lock Piece is at the bottom of the Damper Rod.
A "Cone Shaped" Valve that lets the Fork Oil come into the Bottom of the Fork when the Bike's Forks are extended.

Then the Oil Lock Piece shifts upward to meter the Fork Oil through the Dampers Oil Holes at a regulated rate.
The two washers are on the Damper Rod above the Oil Lock Piece and Prevent the Oil Lock Piece from binding to the the Outside of the Rod ... keeping theh Oil Lock Piece free moving for the next rebound.

The Wavy washer is above the Flat washer.
In the case of three pieces.
The Wavy Washer is Center.

 

Rick,

You have hit the problem on the head.
Those are the three pieces I inquire about.

A question or 2 more

*EDIT* Do the dust seal/oil seal/bush all attatch to the stantion first?
Then the stantion, with those parts attached, silide into the lower leg?
Or is it done some other way?

I know to lube all the parts for ease btw.

*2nd EDIT*The holding tool was not required, just used a 6mm to turn the allen bolt and a 10 mm through the axle hole to hold her from spinning. Worked like a charm!

 

IF you ride yr Bike Hard (with relish) Then seriously suggest you buy and install a pair of Valve Emulators YSSusa.com $135 a pair.
Genuine improvement (you will be impressed) over the pogo sticks in an oil bath Yama/showa fork setup ... but although V well priced for emulators, not free.

 

Thanks dan but I will prob retain the currents setup for now..
I got the bush into the lower leg, I guess I boil the leg then try to put the stantion inside....right?

 

bump bump bump
Someone help me please.
How do i put the lower leg and stantion back together.
What order?>
I think i have done some irreversible things already!!!

Someone has to have the answer, i put the bush in the lower leg and cant get the darn stantion back together,,also cant get the bush out either!!

 

I don't understand what you have done.

PM me with a complete "What you did and are doing"

As for doing ... Stop!
Don't make whatever you did worse!

Just don't panic and start flailing at it ... that usually make it worse!

 

Sorry to hijack, Danilo, where on the site are the emulators. Thought I might like to install a a set, but am having trouble locating a set for my '82 Seca 650. cruzerjd