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ttr 230 fork help please

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so I'm having an issue with these forks. I'm trying to drop the inner tube in after new seal is seated. Do I just bash it in or nah? the metal slide on the bottom of the inner tube catches the inside slide.20190101_190441.jpeg20190101_190448.jpeg20190101_190457.jpeg

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Posted (edited)

Don't force anything, that bushing will never fit thru the oil seal

(if it finally does, you've torn the seal!)

 

I'm not familiar with those forks but typically both the oil and dust seals are first carefully installed on the smaller tube (TTR upper)

the bushing then installed on tube, then the tube slid into the other one (TTR lower)

and then the oil seal driven in place using the proper sized driver (wrapping electrical tape around the tube as a 'driver' can also work)

Edited by mlatour
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BTW that bushing looks like it's way due for replacement,

despite new seals the forks may still leak from too much play in the bushings.

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Posted (edited)

The tubes are assembled first, then the oil seal goes on via a fork seal driver, and then the retaining clip.

You did it backwards.

Service Manual is worth it.

Edited by YZEtc
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 You need to replace or resurface that fork tube if you want the seal to work.

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