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CB900FD forks

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AndyD:
Hi Dave,
Hope you're doing OK.
Yes, that's the 900 sat in the corner waiting patiently for some attention!
Pretty well finished the CJ360T, just needs tweaks and tyres to be roadworthy.
Spent some time doing the XT250 which is also now complete and I really need to get it out on the road to run in as it had a rebore and full rebuild after finding endless bodges and damage on close inspection.
Really should catch up some time if you're around.

Cheers,
Andy

AndyD:
Thanks Bryan,
It's odd but the FD version doesn't seem to appear in a lot of parts lists etc. for some reason.
The FC is very similar and luckily I've also got the microfiche for the FD so have scanned that in which is really useful.
I think I might have worked out what's wrong after a closer look this morning.
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It looks like part 17 should be fixed in the bottom of the fork tube (pt 7) but it looks like it's actually stuck in the bottom of the fork case (pt 14).
This means that the damper (pt 23 etc) can just pull straight through the tube and nothing holds the tube and  case together if that makes sense.
I'll try and get one out later and see if I'm right - never seen this before and always thought that part was 'fixed' inside the fork tube somehow, but maybe it's just just pressed and can come apart with force.
I think the PO maybe just forced / abused the fork assembly until something gave way and came apart, then couldn't figure out why it wouldn't go back together and partly / loosely reassembled it.
Hopefully nothing is damaged
Cheers,
Andy

Bryanj:
Looking at that parts pic i dont think the damper should not slide out of the bottom of the tube, i wonder if the po has got some "different" fork tubes that physically fit but are not right.
As far as i can see there is nothing stopping the sliders falling off the tubes if you raise the bike high enough, especially with air pressure in the forks.

Even if the lower bush is held by circlip it only stops at top bush and that is a lot of travel and would expect damper to come out.

Is it possible there should be a lip on lower bush to stop damper?

Just thinking sideways now

AndyD:
Hi Bryan,
I had another closer look at the parts and also Googled images etc. and I think part 17 is in the right place in the bottom of the slider as the hole through it is too small to slide up over the damper assy.
Like you I can't see what would stop the damper pulling straight through which is what's thrown me - every other fork tube I'm familiar with has something at the base which only allows the damper assy to come out through the top of the tube.
Looking at the fork tube parts online at CMSNL / Ebay there doesn't seem to be anything at the bottom of the tube to retain the damper.
The only other thing that could keep it all together maybe is the top fork bush which is then retained by the ring and circlip up by the fork seal.
I'll try a quick assembly this afternoon and see if that works as I can't think of anything else so far.
Cheers,
Andy

McCabe-Thiele (Ted):
That arrangement looks very similar to my 400NA Super Dream front fork arrangement, mine was the early version with no oil drain screw.

IIRC the bottom plunger was secured by the bottom Allen key bolt.

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