HELP ER6 - Re-Assembling Forks

[wots]

HELP, been trying to re-assemble my forks, but something isn't right.

I slide the damper rod down into the stanchion, then keep it held upside down with a broom handle. Add the silly white cap and insert into the fork lower. I loosely tighten the bolt and slide the stanchion, it moves once then sticks. Take it apart again and the plastic bit is keeping the damper rod in the stanchion where I've labeled in yellow.

I did my NTV forks without issue, what have I done wrong here? I've looked at service manual and even videos, found one on youtube https://www.youtube.com/watch?v=Cs5LnzjHll4 yet I can't see what I'm doing wrong as it kind of skips that bit.
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Currently: Yamaha DT 125 LC2,Repsol Fireblade, and Bumblebee MSX 125

[sickpup]

I don't understand your description but you seem to be making an easy job hard.

Drop the damper into the fork leg and place the plastic cap over the end, put the whole lot into the lower. Using a long allen socket place the bolt on it and the copper washer on the bolt. holding the fork leg the right way up insert the bolt and do it up two or three turns.

Fit the top bush and the seal, insert the spring and fit the fork top loosely. Invert and do the damper rod bolt up with a windy gun, remove fork top, add oil, replace fork top and done.

Yes it really is that easy.

[wots]

That's exactly how I did it the first time, in fact how I did the NTV's. The only reason I inverted things was following the video just to try it. The damper rod just sticks inside the stanchion so you can't 'knock' the seal/shim in. I use the del-boy method with 2 halves of plastic pipe and a jubilee clip and then knock it in. That plastic bit on the end of the damper rod, jams into the bottom of the stanchion. Then the stanchion no longer slides.

It took me about 20 minutes to re-assemble both NTV ones and they are very similar.
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Currently: Yamaha DT 125 LC2,Repsol Fireblade, and Bumblebee MSX 125

[sickpup]

If you push the chrome stanchion hard down into the lower it will jam solid.

[wots]