massive help, thanks bud just what i needed to know.
only prob now is the ally cone in the right leg is proper jammed in.
(someone re-assembled them with the cone in the wrong way)
taking it to work tomoro and if i cant get it out with the bearing press i'm boned

woohoo! success. of a sort. oil lock is now out. only its plastic? and what i thought was the bottom of it is actually a lip, part of the fork leg, that the damper rod retaining bolt sits on. yes, numbnuts here was walloping that lip with all sorts last night, thinking the lock was ally and it was jammed in
never mind, all sorted now, bit of work with a file and good as new
(at least i'll know for next time eh )

RacingSlug wrote:woohoo! success. of a sort. oil lock is now out. only its plastic? and what i thought was the bottom of it is actually a lip, part of the fork leg, that the damper rod retaining bolt sits on. yes, numbnuts here was walloping that lip with all sorts last night, thinking the lock was ally and it was jammed in
never mind, all sorted now, bit of work with a file and good as new
(at least i'll know for next time eh )

↲
glad you got it sorted,do you need an ally cone?i may have one. Cheers dave

thanks Dave but i think i've got away with it.
soon as i get five minutes i'll reassemble the forks;
(saturday gardening in the pi**sing rain, sunday wife was in bed, 'poorly' after her works night out, leaving me with a houseful of pre-teen, e-number riddled, wii obsessed kids )

okay. after much deliberation i have to admit defeat with these forks.
after (2 pages) of drama getting the damn things apart i'm faced with more of the same getting the things together again.
(breaks down in tears )
does any one have step by step info on rebuilding these (that an illiterate stressed out monkey like meself could read??), or failing that the number of a mechanic/garage in stafford i can take them to?
any help would be much appreciated

Where exactly are you stuck?

You just reverse the disassembly instructions (to quote the haynes book)

When you come to put the fork seal in you need to drive it in (piece of drain pipe slightly larger diameter than the fork tube) helps with this else you'll destroy it.

'sup Neo

i've fallen at the first hurdle, i cant seem to get the damper rod retaining bolt (the allen head bolt from the underside of the fork) into the damper rod. i dont have a Haynes and i realise i'm probably being as thick as the proverbial but i want to make sure i'm reassembling correctly.
order i have at the moment is: ally cone, washers, stanchion with damper rod (assembled with top out spring) inside.
ally cone + washers inside bottom of stanchion, damper rod inside, slide stanchion into leg, place main spring inside to retain the damper rod, invert fork, copper washer and allen bolt in place.
i do all that and the allen bolt wont 'catch' the damper rod. do i have to press fit the ally cone into the bottom of the fork leg? seems to be whats needed but if i do that whats the point of the washers? gaaaaaahhhhh

Oh which fork is this from? The internals are different with each fork so you didn't take them both apart and mix them up did you?

Besides that I can't recall having a problem with these forks, the spacer is the correct way around?

the above is listed for the left fork, shorter stanchion, damper rod etc. all the parts went in separate marked boxes.
i'll have another bash when i get chance.
when it was all assembled, the retaining bolt just didn reach the damper rod to screw in?
if i still somehow cant get them back together i'll take it to my lbs, fork out the cash and look sheepish

Hey guys. Started striping my NC21 forks last night.
Was quite a struggle to get the bottom allen key bolt loose. I'm making me a tool tonight to take that thing apart. 24mm bolt head on a broomstick should do the trick.