calli III Fork Seals and adjuster HELP!

[jasoon]

1991 cali III big valve

Replaced the fork seals but I am having trouble with the oil draining and dampening/preload adjuster.
 Ive heard this particular cartridge fork has oil for lube only, 70cc's of dextron atf
First, do I need to remove the cartridge to fully drain the oil?
 Second but more important, I believe I messed up the setup of the adjuster while trying to remove it from the top spring and inner assembly. I was told not to mess with the adjuster but I think I managed to do just that.

If there is a any knowledge of a step by step way to start from scratch and reassemble the fork and top adjuster properly I would be so grateful!
any advice is great.

Thanks!   

[Two Checks]

How did you disassembe the forks and NOT drain the oil?

[jasoon]

I did drain what came out the bottom from the drain plug, but I feel like there is more stuck up in the cartridge

[Two Checks]

The cartridge is a sealed unit. Whatever you drained is all there was.

[twhitaker]

I believe the forks on my '96 Cali are the same. Cranking the adjusters on mine all the way both ways had minimal impact on the damping. Your mileage might vary.

[flangeman_70]

Check this thread :- http://wildguzzi.com/forum/index.php?topic=65449.0

I think it will answer all your questions and disprove a few misconceptions.

Adam

[jasoon]

Thanks flangeman, after another day of fiddling im convinced my damper rod/shock absorber is bent or malfunctioning in some way.

This will be an expensive lesson for sure.

Anyone with a lead on a used bitubo shock absorber??

[Two Checks]

Replace the wimpy Bitubos with FACs.

[jasoon]

Good to know!

Any idea where I can find some?

[flangeman_70]

Where in this world are you located?

[jasoon]

Colorado springs Colorado!

[jasoon]

Flangeman, after another day of thought and wrenching, I think you hit the nail right on the head. it just took me a minute to realize what was really going on!
My cartridge has trouble with rebounding
 Im gonna tear down the cartridge now! 

So before I even get in it I just want to know, it does have oil in it? how much? weight?

is this air gap measurable?

Thank you so much!

[Tom]

Get FAC's damper units and toss the old ones.  Don't even bother with them.  You can buy them from the usual dealers.  Google for parts.

[flangeman_70]

Go to it, you've got nothing to lose 
I am trying 15 weight right now but it is too much. I am going back to 10.
How much? I can't remember  I left a gap to compensate for full compression. You could also measure what comes out but if the seal has failed then it is likely the oil is an ugly emulsion.

Adam

[Chuck in Indiana]

Flangeman, after another day of thought and wrenching, I think you hit the nail right on the head. it just took me a minute to realize what was really going on!
My cartridge has trouble with rebounding
 Im gonna tear down the cartridge now! 

So before I even get in it I just want to know, it does have oil in it? how much? weight?

is this air gap measurable?

Thank you so much!

I used 5 wt, as mentioned in the thread that Flangeman posted. No way to measure the gap, but if you get too much in, it will lock up.

[jasoon]

So you know the forks take atf dextron, 70 cc's

and you say the cartridge takes 5 weight fork oil?

so different oils for the forks and cartridge??

[Two Checks]

The oil in the fork is only for lubricating the slider/seal. The oil in the cartridge is for dampening.  It's jus like the shock on the back. It is actually a cartridge with a coil spring over it.

[jasoon]

cleaned up the cartridge today, works so much better now ;)
still not 100% but I think i can do a thing or two to fix that.

I used 10 weight cause that's what I had, maybe something a little heavier would be better for this application. I see why you used 5 weight now.but I worked with what I had.

Thanks to everyone who helped out I wouldn't have figured this out without you guys!! this problem is now understood clearly and easily fixable.

If I ever find a smoking deal or win the lotto ill upgrade those dampers and springs!

[jasoon]

What should the position of the damper rod piston be when I seal the cartridge? Submerged in the fluid or on top with the rod fully extended?

I feel like this is a basic hydraulics question.

Should I bleed the damper?

[Chuck in Indiana]

What should the position of the damper rod piston be when I seal the cartridge? Submerged in the fluid or on top with the rod fully extended?

I feel like this is a basic hydraulics question.

Should I bleed the damper?

I did it submerged. Had a little too much fluid in it and had to open it and bleed it. I ended up with just a little play in it when it was topped out. I *don't* know if this is correct, just what I did.. :)