front fork reassembly - help!

Hello all.

I'm just installing my emulators and new springs but I'm having some diffculty getting one of the forks back together.

I only partially dismantlerd the forks as i didn't need to replace the seals. So i removed the damping rods and stopped there. All was going well until i tried to reinstall the damping rod in the second fork. It won't go all the way to the bottom - the bottom of the damping rod only goes as far as the bottom of the stanchion. Obviously it's supposed to go through the bottom of the stanchion to the bottom of the fork leg. Then something odd happened. I looked down to see if there was an obstruction and there was a short fat spring at the bottom of the stanchion which is not in the parts diagram. It's very lightweight and i can't see how it has any place in motorcycle suspension (maybe it fell in there?)

I've been scratching my head for over an hour now. Jiggling it around, shining a torch down to see what's going on. Also odd is that i can't see the oil lock piece. i've had other bikes where the oil lock piece would jam itself in the bottom of the stanchion. Is that what could be happening here?

I don't want to take it completely apart as i have no replacement fork seals or bushes and no money to buy them.

Help greatly appreciated!

Cheers

Stu

There is a short spring in the forks, but this'll be on any fork diagram. I'm finding it hard to picture what you have or haven't done from your description.

I think the damping rod is maybe sticking on the spring, due to it not being vertical by the time it's fallen down the leg. Can you keep it upright as you insert it somehow?

Sorted.

The oil lock piece had indeed wedged itself onto the bottom of the stanchion. I shoved a broom handle down there and whacked it and it dropped down to the bottom.

Never underestimate the power of brute force and ignorance.

For completeness: Sam. I had gotten as far as pulling the stanchion out of the fork leg to get the seals out but not actually taken that step. I had only removed the damper rod bolt and pulled out the damper rod. The little spring on the diagram is the rebound spring and the spring i found in the bottom was about one twentieth it's size. fook knows how it got in there but pretty sure it's not supposed to be there.

Sound like its the spring from the check valve inside the end of the stanchion, have the tubes been replaced? are the ends of the tube peened over or is there a circlip, this spring is needed for damping.

[punyXpress]

[quote=stuballs;1801180]Sorted.

The oil lock piece had indeed wedged itself onto the bottom of the stanchion. I shoved a broom handle down there and whacked it and it dropped down to the bottom.

Never underestimate the power of brute force and ignorance.

You, Sir have discovered the secret of sorting any mechanical problem ( & some bodywork ones as well ) on the SV

that little spring is what centers oil lock piece on damping rod. you will not find it on any diagram.
make sure it is all properly seated or you will break it.
oil lock piece is plastic and it swells in oil with time. reason it gets stuck in tube.
we usually take it out of fork.

Originally Posted by zadar

that little spring is what centers oil lock piece on damping rod. you will not find it on any diagram.
make sure it is all properly seated or you will break it.
oil lock piece is plastic and it swells in oil with time. reason it gets stuck in tube.
we usually take it out of fork.

Interesting. I didn't have new fork seals to put in otherwise I would have stripped right down. It's all gone back together ok and it now handles like a dream. I won't be able to really test it until I get onto a track when it warms up. If i have damaged the lock piece presumably terrible things will happen if I bottom out the forks. Suppose I'll find out the first time I give it a handful coming into Paddock Hill Bend.

Thanks for the help everyone.