Fork reassembly issues

[MustacheMike]

I've gone and replaced the seals on the forks, put in new oil, and was in process of putting the forks back together when i ran into this  issue. The picture is of the one forks that will not take this spacer below my thumb into the sleeve, its acting like its too big when its the same piece that came out of it. This spacer is the spacer that should be in the sleeve and not the one that is "fixed" to the bottom of the upper arm, and the piece above my thumb it the washer that the oil seal sits on.

Before I just took it apart again I wanted to see if I was just making a stupid mistake and possibly you guys could help me. The other fork went back together and made me feel like I did something completely wrong with this one, but I did them exactly the same and I don't know why its not going together smoothly, but then again, it is an 81 and nothing goes back together easily back to back haha.

Thanks in advance for the help/suggestions.

[TOOLS1]

Try cleaning the spacer up with some fine sandpaper. It looks like it might be dirty/rusty.
TOOLS

[MustacheMike]

It actually is cleaned off, smooth, but I think it looks dirty because its stained or just had some oil on it. But I did clean it off before attempting to put it back together.

[shinyribs]

The thicker piece is the bushing. It is tight going in to the fork tube. It is more or less pressed in actually. The thinner washer type piece goes between the fork seal and the retainer clip,right?  When I took my 81c forks apart that washer was very loose in the fork leg. Where is it getting stuck at?

[MustacheMike]

When I took it apart the bushing went in first and acts like it needs pressed in but if you do, the sleeve won't fit over the bushing that's fixed on the upper arm.
The thinner washer piece sits on top of the bushing that is pictured.

When I took very thing apart here the parts that are on my fork. From bottom to top: fixed bushing on the upper arm, then the bushing pictured, next is the washer that's pictured, then these following parts are not pictured, the oil seal, another washer piece and then finally the snap ring.

 

[MustacheMike]

Figured it out, made a driver from PVC pipe.

I think it takes becoming 100% pissed off at something before you see how simple it CAN be to do.

[rrgunslinger]

I feel your pain!

On Tue, Sep 11, 2012 at 2:50 PM, MustacheMike [via Honda CB750'S] <[hidden email]> wrote:

Figured it out, made a driver from PVC pipe.

I think it takes becoming 100% pissed off at something before you see how simple it CAN be to do.

Ohio
81 CB750K
82 CR480R

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