Trying to replace oil / dust seals this weekend and follow the service manual instructions.
However, when I slide the damper (shown as "B" in the pic) back in and tighten, I can no longer move the inner leg (before adding oil) and also not able to compress the spring enough to replace the cap.
The spacer is roughly 6" about the fork.
So, tore it all apart again and turning to those with experience.
Forks are OEM Suzuki GSF600
So the damper rod "B" goes in tube "A" small end first, use spring and spacer to push the damper rod to the bottom and check that it travels smoothly.
Install cap onto tube over spring "D" & spacer "E" to hold damper rod from spinning when you bolt into the lower leg. Press down tube and spin to center damper rod in lower leg (check with flashlight)(a phillips screwdriver can help here). Then tighten damper rod screw using a copper washer to seal screw "C" to lower leg "H" Use pvc pipe over tube to seat seal in lower leg.
Did that. Looks like an oil lock is lodged where it shouldn't be
Unless B is being installed from the top, it typically goes in big end up, or first.
Should "B" protrude from the bottom of "A"?
The small end of "B" should come out the end of "A". Allen bolt "C" that fit in bottom of Leg "H" screws in to "B" you will likely need a air gun to spin it fast enough to get it to bite it and lock even with the spring installed you rarely can do it by hand. Use spring or broom handle to push "B" in to "A"
Ok.. I'm not getting "B" though the end of "a" even with a broom handle / press. looks like the oil lock? is stuck inside.
I can spin it, but not get it out.
Put B into the bottom of A backwards from the bottom. If it doesn't fit, figure out why. Otherwise, there is no reason and certainly not any sort of oil or hydraulic lock that would prevent B from poking out the bottom of A. Other than not lining up the pointy end of B into the hole at the bottom of A.
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