34L fork rebuild
 

Hello all,

I'm looking for some help with my fork rebuild. I seem to be at a conflict with the Clymer manual for the fork rebuild.

It is telling me to put the spindle taper on to the cylinder (see pic 1)

1

http://i26.photobucket.com/albums/c1...n/IMG_0033.jpg

and then insert into the fork tube and then the fork leg before screwing in the allen bolt from the bottom of the leg to catch the cylinder.

The problem is, that if I do this, the cylinder wont drop deep enough into the fork leg for the bolt to catch the thread!! (see pic 2)

2

http://i26.photobucket.com/albums/c1...n/IMG_0028.jpg

However, if I drop in the cylinder without the spindle taper and then put the spindle taper into the recess at the bottom of the fork tube it will allow for the bolt to catch (see pics 3 and 4)

3

http://i26.photobucket.com/albums/c1...n/IMG_0029.jpg

4

http://i26.photobucket.com/albums/c1...n/IMG_0030.jpg

Sorry for my complete ineptitude but for the want of trying, I can seem to make these bits fit, if I follow the Clymer manual.

Am I doing something horribly wrong here? Are there further bits that I need to remove from the bottom of the fork tube to allow this cylinder to drop through (see pic 2 again)?

I'm only a beginner mechanic, so please go easy on me!

Good on you!
 

You found a mistake in the Clymer manual. If you follow the manual, and the bolt would catch, no way the fork would move.

So, correct procedure is to insert cilinder into fork leg, threaded end pointing downwards. Put spindle taper onto threaded end of cilinder. Insert he assembly into lower fork leg; fasten bolt. Do not forget loctite and copper ring.

Auke

Auke,

Thank you very much… it has been puzzling me for ages and I was beginning to think I was being very stupid!

Re: the Loctite and copper ring… is this for the allen bolt?

Also, one more question. Is there a trick to stop the cylinder turning as you screw in the allen bolt?

thanks

3 q's
 

Loctite and copper ring for allen bolt - yes.

To stop the spindle turning when fastening the allen bolt - make sure the threads are clean and the bolt moves without resistance in the spindle (till tight, that is obviously). If that does not help, assemble the whole leg with spring and cap to exert pressure on the spindle. That should do the trick - if not you need a pneumatic wrench but be careful - it's repairing a wristwtch with a sledgehammer ...

Auke

Thanks Auke… I feel capable of sorting this out now.

Regards

Andy