Forks apart - am I missing something?

[Phober]

I'm rebuilding the forks on my 09 Hyper 1100. The previous owner had Ohlins cartridges when he wrecked the bike, which he removed after the crash. The stock ones were supplied with the bike, but some pieces were missing. I've ordered everything I needed (from what I could tell), but I'm having trouble with one part.

Parts diagram:


Workshop manual (for 2008, which I understand should be the same for my 09):


The parts diagram looks to be identical to what I've got. But in the manual, it shows #26, which I don't have, and can't find shown anywhere in the parts diagram for 2008 or 2009.

I've currently assembled one fork without it, and it seems okay from what I can tell. #5 fits onto the cap (#3) perfectly, so I'm hoping that's the way it's supposed to be?

Or are you supposed to have the spring fastened into place before installing the cap? If not, what's the purpose of the nut (#7) on #11?

Confused.....please help.

[Ben710]

It´s not in my fork, too. I only have the big aluminum spacer (probably #5 in the workshop manual pic).

edit: by the way, #11 secures the top cap. Screw the cap onto the thread and then counterlock it with #11.

[Thermal Runaway]

Mine is the same as ben's, no #26. I found it odd that the workshop manual showed that bushing (26) instead of the spacer (5). Since this was the only time mine had ever been opened I put it back the exact same way but with new springs and oil.

[Phober]

Cool, makes me feel much better, thanks!

One more question:
How important is it to get the seal seated all the way into the fork tube? I've got it pushed in as far as I can without the proper tool, and it doesn't seem to be leaking - but there's no pressure on it yet. Think it'll be okay?

[Ben710]

If you don´t push it in its seat properly, you will have trouble pushing the dust ring and the spring collar (is that the word?) in its guide.

A good practical tip for seating the oil seal ring: take the old one and put it on top of the new one that you want to install. Then tap it with a rubber mallet. That way you won´t damage the new oil seal ring but you can apply enough force to seat it fully. Don´t forget to coat it in fork oil prior to installation.

On the manual:
Maybe the workshop manual shows the Kayaba forks instead of the Marzocchi!?

[Phober]

Don't have an old seal, as I'm just reusing the original ones.
But I've got the dust boot on, so it should be all good.
If they leak, I'll cross that bridge when I get there.