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I'm a new poster, but I've been using this site for a long time (I wouldn't start a topic without looking for the answer first)

OK! I have an 09 250r and the oil seals needed replacing. I had no previous experience with forks, but equipped with the required tools, the service manual and this youtube video:

http://www.youtube.com/watch?v=vVcKQRjviEE

I went to work... Everything went without a glitch up until it was time to put the cap assembly back in the damper. When I try to push the assembly in (3:18 in the video) the bloody thing just doesn't want to go in. I'm basicaly fighting the spring and it's like the piston won't go passed a certain point (won't go passed the "grooves" under the bleed holes). When I let go, the spring decompresses and my cap assembly sticks out of the damper 1 1/2" to 2". If I try the same thing but with less oil the piston goes in fine so I know it's not a bent or dinged damper tube...

I've emptied the damper and started over 5 times now with the same result every time... I'm about to go mental I'm so frustrated.

I've looked thru all the topics on this board and haven't run into anyone with similar problems which worries me! I'm either the supidest guy on this board (this I could live with)... or there's something realy wrong with my fork!!!

Any help here would be GREATLY appreciated...

Thanks,

Marco

[Asmith]

Fill the damper with 200 ml. of fluid.

Force the base valve into the damper body and turn clockwise while applying pressure until threads catch.

Tighten all the way and then begin the bleeding procedure. The excess fluid will bypass the piston and will come out the bleed holes.

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Thank you... I'll ll try this tonight. So basicaly you say skip the part where I'm supposed to adjust the oil level to 37-42mm following the air purge?

Thx again.

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...Worked like a charm. THANKS SO MUCH, I'll be riding this wknd now!!!!

[Asmith]

...Worked like a charm. THANKS SO MUCH, I'll be riding this wknd now!!!!

Good job.

PS...Love the Happy Gilmore reference...

[[email protected]]

You Like that eh!

You woulda had a real chuckle then if you'd seen me on all 4 in the garage screaming those verry words to my forks at the top of my lungs... ...Wasn't joking when I said it was driving me mental... Neighbors are better about keeping their kid out of my garage now though!!!

Thanks again, Happy trails...

Sick X BTW!