An easy one I expect...forks re-assembling - Printable Version +- Fazer Owners Club - Unofficial (https://foc-u.co.uk/mybb) +-- Forum: Bikes, Hints'n'Tips (https://foc-u.co.uk/mybb/forumdisplay.php?fid=66) +--- Forum: FZS600 Fazer (https://foc-u.co.uk/mybb/forumdisplay.php?fid=78) +--- Thread: An easy one I expect...forks re-assembling (/showthread.php?tid=79513)

An easy one I expect...forks re-assembling - Geedog - 11-04-18 So I thought I’d be ok doing this but after a week waiting for the seals to arrive it seems i’m Stumped getting them back together..or have forgotten a step.. New seals and dust caps are on and top fork is in bottom fork nice and snug.. The next step - I thought was to put in the damper rod along with its spring and screw in the bottom screw/plug from the end of the bottom fork...on doing this - the top fork is now fixed with no movement which cant be right.. Am i being dumb? What have i done wrong ? (Apart from leave it to a professional..!) :eek Re: An easy one I expect...forks re-assembling - His Dudeness - 11-04-18 There's a good write up here http://foc-u.co.uk/index.php/topic,42.0.html Re: An easy one I expect...forks re-assembling - Geedog - 11-04-18 Thanks Dudeness, I had seen that one and the only thing I can identify is that maybe fork is stuck, however on unscrewing bottom screw the forks separate with no trouble at all, when the screw is in - no movement.. Re: An easy one I expect...forks re-assembling - His Dudeness - 11-04-18 It's a good while since I did fazer fork seals so you'd be better off waiting for someone else to reply but if I remember correctly if you let the fork fully compress it jams up solid and you have to force it apart. Re: An easy one I expect...forks re-assembling - bandit - 12-04-18 Geedog, here's the same link as His Dudeness posted but with more pics, The bronze upper fork bush may not be seated properly see link. [size=0.7em]https://www.tapatalk.com/groups/fazerowners/howto-forks-seals-bushes-and-oil-t23188.html[/size] Re: An easy one I expect...forks re-assembling - Jamieg285 - 12-04-18 It's very easy to jam the upper and lower together.  I think I put the damper/lower bolt on before adding the seals. Don't know if that helps or not. A number of times I had to go back to the vice and hold the lower whilst yanking on the upper to release it. I also think I only did the bottom bolt up loosely (but enough to seal the oil) until the springs were fitted, then did the final tightening at the end. Re: An easy one I expect...forks re-assembling - Triggergee - 12-04-18 I had this problem a few days ago after doing the fork mod. All you need to do is once the damper rod is screwed in and your getting no movement re-fit the fork into the bottom yoke and tighten it up. Using a rubber mallet or a small block of wood and a hammer gently tap down on the brake calliper mounting lug or on the side of the fork where the dust seal is and it will free up. When it's stuck you'll have the white plastic bit jammed into the bottom fork upper/stanchion like in the first picture and you need to tap it out like in the second pic. It jams in very easily so be really careful not to push the stanchion down into the slider as you assemble everything. Re: An easy one I expect...forks re-assembling - Geedog - 12-04-18 Thanks all, I managed to unstick them, I needed to be a bit more brutal..! Back on the bike now and looks like no more leaky seals  Re: An easy one I expect...forks re-assembling - redsed - 17-08-19 Thanks for this post, saved my bacon. Just could not figure out the issue until I saw this. Cheers.