Fork assembly problem :(

[loply]

Hi folks,

I took one of my USD forks from my Yamaha SZR660 (same forks as the TZRs) apart today to change the fork seal. Ive done this job once before.

When I go to reassemble the fork, when I bash the gold ring with the teflon inner coating into the fork tube, the slider gets stuck.

As soon as you bash the gold thing half way in or more, the slider gets totally stuck solid and is a bastard to remove again.

Any idea what this could be? Its driving me insane, I hope I dont need new forks.

Ill post a pic tomorrow.

Rich
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Yamaha SZR660 Caution to the wind, the throttle pinned!

[zenodamper]

...this gold bit with inner teflon coating would be the guide bushing, right? If it is getting stuck, you will most likely be needing a new one, and some dressing on the seat... Maybe getting a set of fork seal drivers would be a better way to put the stuff back in... save more future problems from happening.

[loply]

The guide bushing yeah, its not getting stuck itself - The bushing goes in fairly easily, but once its in, the fork wont slide...
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Yamaha SZR660 Caution to the wind, the throttle pinned!

[zenodamper]

Ya, and on the flip side of your problem, is the bushing that goes in easily enough; but the fork gains another kind of problem - in other words, the tolerance/clearance is quite important... so, take a good look at which bit has the problem, the bushing or its seat, and more than likely you will need to change that bushing.

[loply]

How much does a guide bushing cost normally?
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Yamaha SZR660 Caution to the wind, the throttle pinned!

[zenodamper]

That is an excellent question; but alas, I have not been back in the UK long enough to have had to purchase any... I would imagine, by converting from AUD, around a tenner...

[loply]

Replacement guide bush is around £20, but the guy at the parts shop reckoned a worn guide bush would cause free play in the stanchion, rather than causing it to jam...

I kind of agree with that theory; Why would a worn bush cause it to jam?

Then again, what else could it be?

I don't have £20 to waste if it's not the bush, but I can't explain it really... Any other thoughts at all?
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Yamaha SZR660 Caution to the wind, the throttle pinned!

[zenodamper]

There is the worn bushing scenario, and there is the 'been banged in lots of times' bushing situation whereby the edges get a little warped, and end up pinching on the fork staunchion... Or even, the seat/ledge area of the outer tube could have gotten nicked or damged, which in turn will also squeeze inwards... It is very difficult to know without feeling it for myself, as there could be other reasons as to why things are not as slidey as they should be...

[cagiva gezzer]

Did you keep all the parts from each leg together? i.e. , have you swapped parts from the left leg to the right? Upper and lower bushes?
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"because one stroke isnt enough and four strokes waste two"

[loply]

No, I only took one fork apart, and put the same parts back in. Ive only put two parts in (upper bush and lower bush), so theres no question of things being in the wrong order...

Its ridiculous - It slid before, so why doesnt it slide now?
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Yamaha SZR660 Caution to the wind, the throttle pinned!

[Nath]

I know it's obvious, but are you sure you're bashing it in square?
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Hard livin', hard luck.

[cagiva gezzer]

You've done it before, it worked.

You've got the manual.

[loply]

I bash it in evenly until it fills its seat, so it must be square.

Im going to remove the bush later this evening and closely examine it for damage, twisting etc.
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Yamaha SZR660 Caution to the wind, the throttle pinned!