I'm in need of some help from the Fork Guru(s)...............................

[Firehawk068]

I am in the middle of the fork rebuild on my '90, and I am ready to start the reassembly process......................I ran into something that has me a bit miffed.........

This is the second time I am rebuilding them myself. The first time was a little over 4 years ago, and at that time I followed the procedures outlined in Mark Martin's write-up on the installation of Cartridge Emulators............I printed out the write-up 4 years ago, and put it in a 3-ring binder for future reference. I have been following along these notes during the disassembly, as well as referring to both my Haynes manual and the factory Yamaha service manual (they both lay out the exact same information on this)

As I am reading through the installation procedure, and taking inventory of all the pieces (to familiarize myself with the process before actually starting assembly) I notice that I seem to be missing something.........................

The parts in this picture (labeled 11,12,and 13)



And in this picture (labeled 3,4,and 3)



Yamaha calls them (2) Wave washers, and a Plate washer.
They are supposed to be installed between the Taper Spindle (#14) and the Damper Rod (#8)

These were not there when I disassembled the forks.........................And I don't remember them being there when I rebuilt the forks 4 years ago either........

The procedure outlined in the write-up does not mention them being installed during reassembly, nor does it show them in the picture............



Yamaha shows them in the exploded view that states '84-'90............................And refers to them in the instructions for fork assembly for '84-'90......
The '91-Up forks show slightly different internals, and do not show these washers................It also does not have the Taper Spindle shown, but a similar piece called the "Oil Lock Piece"
#9 in this picture................



Mine resemble the '84-'90 fork diagram (except for the anti-dive)

Has anyone rebuilt theirs recently, and might recall if these washers are in there?
Or maybe someone, possibly Randy, who may have rebuilt numerous forks and are quite familiar with all the internal pieces?
Could it possibly be that some years (maybe the anti-dive years) have them, and some years do not?

Anyway, tomorrow I'll see if I can locate my notes from 4 years ago to see I mentioned anything about the washers to myself..............

[movenon]

No washers in my 1990 Alan. I think it is an ABS thing... N/A in the 88-90 FJ's.


And for those that are reading the thread,   the thread by markmartin is http://www.fjowners.com/index.php?topic=1911.0

George

[chiz]

The second parts diag does not appear to have the long rod attached to the top fork nut. Yet the non anti dive forks that I purchased off EBAY did have the rod {used to adjust damping}  the wave washer bits weren't there.
Chiz

[fj1289]

Alan - loks like the function of those parts would be to help reduce friction/binding when turning the adjustments on the top of the fork.  If they weren't in there since the last rebuild and you've had no issues, I'd press on without a second thought.  Except to maybe to add a note this time for the next time you're in there!

[racerrad8]

Alan,

Yamaha stopped using the three washers starting in 89 according to the parts manual.

I personally do not use them on the early forks as well. 99% of them are missing or damaged as they come in with the taper spindle wedged into the bottom of the slider and the washers can be found on either side all screwed up.

Randy - RPM

[FJ_Hooligan]

I remember them having something to do with the anti-dive. 
They allowed the tapered spindle move slightly and expose the oil flow holes under the spindle? 
I may have come to this conclusion on my own since one of the ways to disable the a/d is to drill additional holes above the spindle.

[Firehawk068]

Thank you guys!
You guys all rock!

I shall be assembling my forks this evening (without the washers that I wasn't missing in the first place)