RTFM (was "Well, I'm stumped")

I had this problem with the YZ'sorks in that they suffered from a lot
of stiction.

My original plan was to get a man in, but then I had a bright idea:
why not get a workshop to dismantle them, then I could easily take
measurements and make up a suitable tool for rebuilding them.

This would save one trip to a MX dealer. Cunning, eh?

So, I took the forks in to the Bavins in Diss, and they were taken
round to the workshop. A few moments later I was called into the
workshop and told: "You do know that you only have to remove this clip
here, warm 'em here, stick 'em in a vice and pull 'em apart, don't
you?

D'oh! I'd though that a special Kayaba tool was needed.

In fact, they don't even need all that heating/vice work, they come
apart with a couple of sharp tugs just like conventional forks.

The upside was that I did get to pick up the seals and sliders and
also (with permission) bounced another YZ to get a feel for how they
should be. I also got some useful advice on fork oil - I never knew
that they did a 2.5 weight, for example - and other suspension setup
stuff.

On the way home, I realised that I'd managed to loosen the compression
valves during my attempts to open the forks up and to retighten those
I really did need the special tool.

Luckily, by peering down the fork legs I was able to guesstimate the
size of tube needed, and made one up.

I now have TWO specialist fork tools which I may need but rarely.

Then I found that Bavins had supplied one seal in the wrong size. They
had the correct one delivered to me courtesy of the Royal Mail the
following day, though.

At the end of it all, at last I have rebuilt forks with new sliders
and seals and they are smooooooth.

Yeee haaa!

 

Along the lines of "shit in the carbs" I suspect!