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Here's my new spring spacer next to the original.
Now we'll reunite the upper and lower fork tubes. Put a plastic baggie over
the top of the lower fork leg and lube it up with some fork oil. this will
keep the seal from getting cut on the sharp edge where the bushing sits.
Slide the seal carefully over the bag (the spring side of the seal faces up,
or left in this photo), then put on the washer.
Next the bushings go back on. The top bushing will snap into place in its groove.
Slide the upper fork tube on. The lower bushing will go down into the tube.
Use the washer to tap it into place with a punch, or if you have it, use a
fork seal driver.
Next, use the punch or seal driver to seat the fork seal. Replace the clip and
the dust cap.
Now you're going to fill the fork tube with oil. The Race Tech website should
have given you a fork oil level. This is actually measured by how far the oil is
from the top of the outer tube, when completely bottomed out, with no spring in
the fork. You can use a fancy syringe tool for this, or do like I did and measure
the distance on a screwdriver and put a piece of tape around to make it a dipstick.
Pour a little oil into the fork leg (maybe a cup or so).
Now you have to bleed the damper assembly. Slowly pump the damper rod up with your
fingers until there's no more air bubbles coming out of it, only oil. If you need to,
add a little more oil. When you're finished, add more oil until you have the correct
oil level.
Now slowly drop your Race Tech spring into the fork. The tapered end needs to go up.
Put the lower plastic spacer piece on your new spacer and lower it into the fork.
Now is the tricky part. You have to compress the spring enough to get a set of vise grips
on the damper rod nut. I used a long skinny screwdriver, while having a friend hold the
damper rod and clamp the vise grips down.
Once the vise grips are on, put the upper plastic spacer piece on, then the washer, then
the fork top. Get the threads started, then use your large wrench to tighten it down.
Remove the vise grips and let the spacer pop into place.
Slide the outer fork tube up and screw the top down. Your fork is back together!
Now you can set the compression adjustment (bottom) and rebound (top) according to the
Race Tech recommendations, and install your forks. Set the sag to your preference
(25-35mm) and enjoy your new forks!