Hi! We're swapping the forks across from one frame to another on a '99 FZX250 Zeal. Unfortunately, the steering was disassembled a few weeks back and the parts put into plastic bags without any photos or notes taken. So: a few weeks laters we've reassembled the bearings OK but we're stuck with the locknuts. The parts diagram shows a washer (numbered 8 in the screenshot) between the top and bottom locknuts (#7 in the diagram), but the washer we have is rubber, not metal. We had assumed that this is a seal. Is this correct? Is the washer between the locknuts meant to be rubber? Thanks! Duncan
I just checked the parts diagram on megazip. Part #8 is meant to be a metal washer, not rubber. In your case, I would forgo the washer. The lower locknut applies preload to the steering bearings, so get that adjusted first. I would then put the second locknut on top of it with no washer, and tighten until the gaps line up with the first washer (if possible). Then add the 'special washer' / lock washer. I would put the rubber damper piece between the washer and the top clamp (many newer bikes have this arrangement). Have the forks tightened in the lower clamp first, then tighten the top nut on the top clamp, and finally tighten the fork clamps on the top clamp.
