1989 Fork re-assembly question (possibly silly)

[uhfradarwill]

I'm about to reassemble my forks after acquiring new seals. I've done a fair amount of searching, watching that youtube video, and staring at the illustrated parts breakdown, but the answer eludes me.

It's my understanding that the "SPINDLE,taper" and the wavy-flat-wavy washers are installed in this fashion:

 

 

 

My question is how in the hell do these stay in place, and not just slide off the inner shaft while you slide the outer fork tube up?

 

The hole in the "plate, seat" is almost the size of the inner shaft. Will it seat a little higher if I take a socket and tap in on to the bottom of the inner shaft"

 

Thanks for any help.

Will

[BlueSky]

Does this help?

 

[Marcarl]

My recollection is that you have the spacer upside down. Things are all held together by the allen head bolt being threaded in from the bottom. The upper part, the part sits inside the tube to which the bolt is threaded can be held in place with the end of a broom handle after you line everything up and slide it into place.You can then hand turn the bolt to make sure it spins in the threads properly and finish up with an impact. Make sure you have the copper washer in place on the bolt. If you like to do things by hand then you can double nut a bolt with nuts that fit the broom handle end and then use an extension and socket.

Flat washer in the middle, wavy washers on top and bottom.

[uhfradarwill]

Does this help?

 

 

No, not at all.

I've watched your video numerous times and you never show just exactly how you accomplish the task I originally asked.

Actually it looks like you don't have the bottom bolt in when you are driving your seal. This makes me wonder how all that banging didn't dislodge the parts I inquired about.

 

Thanks

Will

[MiCarl]

Your assembly order is correct. Here's the trick to putting it together:

 

 

1. Install the damping rod inside the inner fork tube.
   
2. Install the fork spring in the inner fork tube.
   
3. Install the fork cap a few turns to hold the spring and damping rod in place.
   
4. Hold the inner fork tube assembly with the damping rod pointing up.
   
5. Install the springs and taper spindle as you have in your picture.
   
6. Lower the outer fork tube over all that stuff and install the damping rod bolt with locking sealant.
   
7. Torque the damping rod bolt.
   
8. Remove the fork cap and spring.
   
9. Install upper fork bushing, seal and dust seal.
   
10. Add fork oil
    
11. Reinstall fork spring and fork cap.
    

[BlueSky]

No, not at all.

I've watched your video numerous times and you never show just exactly how you accomplish the task I originally asked.

Actually it looks like you don't have the bottom bolt in when you are driving your seal. This makes me wonder how all that banging didn't dislodge the parts I inquired about.

 

Thanks

Will

 

Well, it ain't my video. I watched it a couple years ago and googled it for this thread hoping it might help. Sorry. I assume you have looked at the dwgs in the manual or on partzilla or similar parts web sites?

[BlueSky]

I just assumed you would look at video #2 since the one I posted was #1 . Video #2 does cover those parts you are questioning.

 

[Prairiehammer]

I'm about to reassemble my forks after acquiring new seals. I've done a fair amount of searching, watching that youtube video, and staring at the illustrated parts breakdown, but the answer eludes me.

It's my understanding that the "SPINDLE,taper" and the wavy-flat-wavy washers are installed in this fashion:

 

 

https://www.venturerider.org/forum/attachment.php?attachmentid=116275

 

My question is how in the hell do these stay in place, and not just slide off the inner shaft while you slide the outer fork tube up?

 

The hole in the "plate, seat" is almost the size of the inner shaft. Will it seat a little higher if I take a socket and tap in on to the bottom of the inner shaft"

 

Thanks for any help.

Will

 

Will, you mention the "plate, seat", but it is not pictured. The "plate, seat" is used on 1988-1993 Ventures. You are working on your 1989, right? The "plate, seat" often remains at the bottom of the lower leg interior upon fork disassembly because of the rubber seal/lip on the "plate, seat" creating a seal. If you don't have it out of the lower leg yet, fish it out and examine it. The rubber lip is sometimes damaged.

If the seat plate is good, then lightly grease all those loose components to stick them together and on to the "spindle, taper" and slide the whole assembly down into the lower leg in one smooth motion until the assembly bottoms out in the lower leg.

 

Attached is a diagram I made, showing how the 1988-1989 assembly should be. Also attached is Bob K's photo of the damping rod assembly, but with out the "plate, seat".

 

[uhfradarwill]

Will, you mention the "plate, seat", but it is not pictured. The "plate, seat" is used on 1988-1993 Ventures. You are working on your 1989, right? The "plate, seat" often remains at the bottom of the lower leg interior upon fork disassembly because of the rubber seal/lip on the "plate, seat" creating a seal. If you don't have it out of the lower leg yet, fish it out and examine it. The rubber lip is sometimes damaged.

If the seat plate is good, then lightly grease all those loose components to stick them together and on to the "spindle, taper" and slide the whole assembly down into the lower leg in one smooth motion until the assembly bottoms out in the lower leg.

 

Attached is a diagram I made, showing how the 1988-1989 assembly should be. Also attached is Bob K's photo of the damping rod assembly, but with out the "plate, seat".

 

https://www.venturerider.org/forum/attachment.php?attachmentid=116289https://www.venturerider.org/forum/attachment.php?attachmentid=116292

 

Very awesome, thanks Mr. Hammer. A dab of grease is exactly what I did!!

 

The funny thing is that no matter how good of a job you do on the fork seals, a cracked rubber air line at the top of the fork will ruin your day.

I ordered some replacement lines off of ebay.

 

Will

[Bob K.]

 

 

 

It all goes together pretty easily if the forks are off the bike. Grease was the trick I was taught, too, if the inner forks are still on the machine.