So I rebuilt the forks on my ’06 DR since the fork seal were leaking. I just want to double check that I did it right.
I replace both “inter tube metal” and “outer tube metal”. The “inter tube metal”, what I would call the piston, was oblivious and snapped into the end of the inner tube. The “outer tube metal” looks like it just floats on the inner tube below the seals?
The “oil lock piece”, a white plastic tube, I inserted into the bottom of the inner tube with the tapered side “up” and then dropped the damper rod into the inner tube and into the oil lock piece. Then the washer, “retainer”, that sits below the oil seal and dust seal and then put the inner rod assembly into the outer tube and used the 8mm bolt to fasten the dampening rod to the outer tube. I used a 2” PVC coupler that I machined down a little to then seat the oil seal and dust seal, and installed the “stopper ring”.
I then Filled the fork to 6.5” below the top of the inner tube (I used a 12” scale as a dip stick to adjust the level) with the spring out and the inner tube fully compressed. Put the spring back in, a washer, the spacer, another washer and the cap.
It seems right but I have a slight friction noise when I compress the forks. I’m not sure if this is normal or if did something wrong?