by mextitan » Fri Oct 28, 2011 10:42 pm
ok, so I finally figured this out. The bottom clicker goes into the damping rod. The top part of the damping rod goes into the rebound adjuster which is in the top chamber. Sorry, but I dont know the proper terms. Anyways, you have to open the chamber and remove the gold part that bolts to the bottom clicker. You remove that part from the chamber. It slides out through the top part. It is going to be a long rod as well which is where the damping rod goes into. Make sure to put some grease at the bottom of the outer rod so it slides out smoothly. Bottom part you have the threads where the bottom clicker bolts on to and on the top part has a black piece on it. You have to heat the part below the black part with a torch to soften the thread locker. Once you heat it up, you will hear a light click meaning that it has completely loosened up. Unthread that part and there you will see the rebound adjuster. With some pliers, turn until you it hear loosen up...
Once you have loosened it up, look at both ends of the damping rod. Most likely one of the ends is going to be completely round. Note that the rod has to have a flat side to it on both ends.
What happened? When you were rebuilding the fork and you inserted the rod, most likely it got inserted wrong tightening the rebound adjuster at the top part and making the tip of the damping rod completely round.
One, you can either replace the damping rod or, two you can lightly tap on the damping rod until you get the side flat again. I recommend just replacing the damping rod.
When putting the part that you heated to separate, make sure to put some red thread locker again and put it back together.
Rebuild your fork again and try it one more time. This should work now.
I had this problem on my bike and took it to a suspension guy who took it apart and showed me the problem. It looks fairly easy but it is time consuming. Be patient when doing this. Sorry I couldn't take pictures but, next time I change the oil to my forks, I will take some pictures to should you guys how to do it. I really hope this helps someone out... Good luck...