we cant seem to get it to hook up with the screw on the bottom..

AIM me @ ManjulBose
Yahoo @ microbose

we are stuck!


Edit: We fixed it.. look below.

can't help except to offer the search function...

if you can get to a hardware store buy a 7/8 inch nut and dop it down the tube and put a matching socket inside with enough extensions to connect a ratchet

the top of the dampening rod has a 12 point socket end on it

this worked for me

one last thing you may need to grind on the nut a little to get rid of the tapered edges

Well its fixed..

a call to srinath and we still didnt have an solution..

Turns out there is this "spacer" on the inside, that for some reason was either not on the damper or was doubled up. IN either case once we figured out what was causing the damper not to go down all the way we were able to put back the forks.

full report coming soon.

Once again a big thank you to kerry.

i guess i didn't understand your problem

Quote from: Mati guess i didn't understand your problem

Well, it's kind of embarassing to explain....

For whatever reason we decided to pull both forks at the same time and work on them in parallel.  After dropping the fork dampers out of both forks and pulling the fork tubes and installing new oil seals we started putting everything back together.  On the first fork we couldn't get the retaining bolt to grab the threads on the lower end of the damper - for over an hour!  We finally tried the other fork and it went together just fine, but we noticed that the 2 inner tubes protruded different amounts from the outer tubes.  

In the end we pulled both forks apart again and looked down inside.  One of them had item #10 from THIS BikeBandit diagram still in the bottom of the outer tube, while the other one didn't.  (DUH!)  We swapped inner tubes and everything went back together with no problems.  

MORAL: When the book says to do one fork at a time to avoid mixing up parts, pay attention!