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Discussion Starter · #1 ·
Hey, I've a problem. Here's the fork scheme: http://www.riderforums.com/attachme...6251702-fork-assembly-problem-c1917_f2340.jpg
Precondition: while disassembling, I was screwing allen bolt 44041 in wrong direction, tightening it.

Once fork stucked compressed after oil drain, but it's common issue, and it unstucked a bit later.

I was replacing seals so I've disassembled fork with no problems.
After seal was replaced I've started to aseemble fork. But when cylinder was screwed with bottom allen bolt fork stucked in lower position again. Cylinder can't move from inner tube, and seems like it's because of stucked cylinder base (check attachment).
It can't be pulled away, I can't pass cylinder cone through it completely to screw it with allen bolt and fork always stucks in the lower position.

I've tried to jerk it out: me and my father were holding tubes and we were trying to pull them away, but with no result.

Btw while trying to remove cylinder base from inner tube some spring (check attachment) dropped out from inner tube. Is it from valve and how to deal with it?

I found such problems: http://www.riderforums.com/zr-7-maintenance/84999-fork-assembly-problem.html http://www.riderforums.com/zr-7-maintenance/96650-fork-oil-replacement-fork-stuck-collapsed.html
 

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Discussion Starter · #2 ·
Friends, no solutions? Weekend is coming so there is one more chance to complete my fork assembly.

Is it possible to use brute force to unplug cylinder base from inner tube? How strong this cylinder base is?
 

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Discussion Starter · #3 ·
Cylinder base has cone profile.
I did it using 12mm socket which is pretty ajust into the cylinder base. Socket was thrown into inner tube and was pushed with long pipe to knock base out.
 
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