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Discussion Starter #1 (Edited)
I am in the middle of replacing my stock springs with Race Tech Gold Valve Emulators and springs. Guess I didn't read the directions right and took the forks all the way apart. Apparently I could have just undone the Hex head at the bottom of the fork and that would have released the dampener rod in the very bottom. But smart me removed the dust seal, oil seal retainer etc. So now I am at the point where I need to put it all back but don't have the special Fork installer to pound it back together. Is there any way to do this? Without the special tool? Please help... Thanks

Here is a photo of what I need to put together that requires a special tool..

 

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Buy the tool, you won't regret it, but you can do the job without it.
 

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You can carefully push the bushing into place with a drift punch. Work around the bushing a little at a time tapping it evenly into place.

Did you remove the damper rod? If you don't have an impact wrench to spin its bolt in, try an electric drill with the long 6mm bit chucked up. Don't forget the copper gasket, and clean off all the oil and use a drop of blue Loctite on the threads. Or, put the fork together with the spring in place, then insert the damper rod bolt; the spring will hold it to get the bolt started. I've been in a dampening rain, but I've never seen a dampening rod.
 

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Discussion Starter #5
Yes dampener rod was removed and enlarged to 7/16" holes and reinstalled. I don't remember a copper washer anywhere. Where does that go. Also with the drift punch can I use a flat head screw driver instead? I don't have a drift punch..
 

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Yes dampener rod was removed and enlarged to 7/16" holes and reinstalled. I don't remember a copper washer anywhere. Where does that go. Also with the drift punch can I use a flat head screw driver instead? I don't have a drift punch..
Almost certainly not. Your flat head screwdriver is going to be far far harder than the bushing material and unless you have the touch of a pickpocket, you'll booger up the bushing. I'd suggest you take it to a friendly local bike shop and have them put them back together for you if you can't wait for the tool.
 

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Discussion Starter #7
Sorry I don't know what all the parts are called but I needed the piece that is under the Flat Washer to be pressed into the fork. The seals just slid right in with hardly any resistance. I did end up using a Flat head screwdriver on top of the Flat Washer and worked my way around in a circle. I put some silicone spray inside the tub before seating the piece first. Worked like a charm... Hope I didn't booger anything up..
 

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Discussion Starter #8
Crap, just realized it wasn't silicone spray I put down the fork tube to help things slide in it was Teflon chain lube. Should I pull everything apart and just coat it with fork oil the next time? Will the Teflon spray jack things up inside?
 

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Crap, just realized it wasn't silicone spray I put down the fork tube to help things slide in it was Teflon chain lube. Should I pull everything apart and just coat it with fork oil the next time? Will the Teflon spray jack things up inside?
Nope

Pete
 

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a flat screw driver to push the bush apart a bit and a healthy dose of silicon spray got mine on without issue.

the annoying part is seating the oil seal- with tools is a 20 second each side job, you can fabricate a home tool like that outlined in one of blacklab' thread or just pay $10 for your local shop to do it - they could do the whole slide the bushes, and seating the oil seal in less than 5 minutes both side.

have fun either way

yes. damp vs dampen - ok for the average bike to misuse the word - it's a big worry when suspension specialists confused the term, you start to worry about their ability.
 

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I'm afraid that my reply might be a bit too late, but here it is:

I made my own "suzuki special tool" to drive the seals onto the suspension bottles. It is basically a PVC pipe cut in half so it can fit tight against the fork tube. I filed the lower end so it would fit in the space between the bottle and the tube, and of course, it is longer than the tube. Put the seal in place and push it as far as it will go with your fingers (do not use a screwdriver or any other metal tools!) then lay the pvc pipe halves tight against the tube and gently tap the top with a hammer. It will push the seal down evenly into its position.





p.s. Make sure both the tubes and the pipe are clean unless you want to scratch the tubes. It is also a good idea to lube the inner side of the PVC pipe with some oil, also to protect the tubes. I used the old oil I took out of the forks.
 
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