'81 Maico Fork Rebuilding Question

[GT350]

I need to re-install these four piece in the bottom of my '81 chrome fork tubes:

-Large aluminum piece, one side is recessed (visible on top in photo) and one side does not have large recess (visible on bottom in photo)

-Small aluminum piece with one side flat (visible on top in photo) and one side is flat (visible on bottom in photo).

-Washer with four prongs

-Clip (obviously installed last)

What is the correct re-install order for the two aluminum pieces and washer, also what direction do the aluminum pieces go since each the sides are different?

[sleepy]

From memory the top items in your photo go in as they are. The stepped washer in with step up into the large recess then the funny shaped washer, put that assembly into the fork tube facing up and clip underneath.
If that doesn't work I pull one apart and have a look.

[Brian Watson]

does the parts book not show in detail what the assembly order is.. I know in the Swedish bikes I play with the drawings for components like this are quite specific and you can follow the assembly order / pattern from that..

[GT350]

Is this correct order:

-Large aluminum piece with non-recessed side inserted first into chrome fork tube bottom
-Small aluminum piece with flat side inserted into recessed side of large aluminum piece
-Washer (4 prong) with step on small aluminum piece facing washer
-Clip resting on the washer when assembled

What confuses me with the above setup is the small aluminum piece rattles around in that recessed area of the large aluminum piece both side-to-side and up/down. With damper rod passing through small aluminum piece it would have travel up/down in that recess area.

Correct me if I'm wrong!

Thanks!

[sleepy]

Is this correct order:

-Large aluminum piece with non-recessed side inserted first into chrome fork tube bottom
-Small aluminum piece with flat side inserted into recessed side of large aluminum piece
-Washer (4 prong) with step on small aluminum piece facing washer
-Clip resting on the washer when assembled

What confuses me with the above setup is the small aluminum piece rattles around in that recessed area of the large aluminum piece both side-to-side and up/down. With damper rod passing through small aluminum piece it would have travel up/down in that recess area.

Correct me if I'm wrong!

Thanks!

The other way around. The 4 prong washer goes in first then the stepped washer with the flat side down, then the alloy piece small recess up and the clip holds it in. The stepped washer is a one way valve for the oil when the fork is traveling outwards. The large recess needs to be on the bottom to let the bottoming cone fit up into it.

[GT350]

Let me try this again!

Assuming chrome fork tube is facing same direction as installed on bike (bottom facing down):

-Four prong washer goes into the bottom of the chrome fork tube first
-Small aluminum ring with step in direction (up) of four-prong washer
-Large aluminum piece inserted into fork tube with recess going in first (facing up) so small aluminum piece rests in recess with flat side facing down when forks are assembled on bike.
-Clip installed resting against non-recessed side of large metal piece

Does that sound correct?

[sleepy]

yes

[GT350]

Thanks! I can finally see how this valve works now.

[LWC82PE]

Looks the same as Simons forks except they have 3 instead of 4 tabs.