Correct Husky Damper Rod Assembly

[PEZBerq]

Just installed the forks in my 240 WR resto project and discover they are topping out with a clunking noise.     :PSounds metal to metal.  My 430 doesnt do that so I guessed I screwed up the assembly. 
I have stripped them down and want to confirm where the plastic top out washer is supposed to be positioned.      The spares manual is not clear on this.
I had it in the groove near the end of the damper rod however that allows the damper rod to go metal to metal with the spacer seat located in the end of the fork tube. 
I attach two photos of each option as I see it.  Can anyone please tell me which location is correct?   I had 10W fork oil 150mm from the top of the tube with forks collapsed, no spring.  Thanks

[PEZBerq]

Second photo

[YSS]

Yes we know the problem , we make a new rod at the same time we install the PD valve .
Perhaps it was cheap and good enough at the time .

[PEZBerq]

Yes Walter I'd like a set of PD valves one day.  But for now which is the correct position for the plastic washer?

[YSS]

Just ring me , this can go on for ever

[LWC82PE]

isnt there top out springs? maybe you need heavier oil?
isnt the plastic ring the wear/piston ring that goes on the end of the damper rod?
i can see reasons to have it in both places. you will just have to wait for a husky expert to let you know or ask Walter

[grouty]

When I first bought my 78 390WR many years ago I had the same problem. After a rebuild it was exactly the same "clunk". There are no top-out springs on them. I have been told that this is normal, but don't agree. So I will be watching closely !

[YSS]

When we install the new rod set up that includes topout springs . Its better with springs.

[LWC82PE]

i just had an idea, you could try using some four stroke valve springs

[YSS]

Thats not possible with the standard rods , since you would loose about 40 mm of stroke

[LWC82PE]

yeah i know. i was kind of thinking i should of mentioned that aswell so your new rods and springs should be the go to fix it up.

[husky61]

What year model is the 240 WR

I have two of the 83 Model 250 huskies.

one XC 250 and one CR 250 and the shocks are perfect . No top out , no clunking , in fact nothing but a smooth action.

Same for the 84 model ,although these have different forks same for the  81 model  79 model , 78 model , 76 model , 74 model and 72 model so it must be an assembly issue.

[PEZBerq]

Rob it is an 84 model.  Damper rods have same part number for 83 and 84 models. Can you tell by photos which way is correct for the plastic washer?  Also what weight oil do you run.  I put 10W in the 240 and 15W in the 430.  Is 10W tool light for the damper rods to not top out with a clunk?  Cheers

[husky61]

We run 20 weight oil in the 250's and 500's.

Im not sure on the position of the plastic washer but Frank Pons at biketek or Fernando at Husky parts would know.

[Oppet]

Howdy

This I have found on the other site http://www.pastasoft.se/hva/goodstuff.htm theres some manuals
When you put the rod bag you shouldnt fix it until you are sure that tube goes well in there after that fix the bolt.

Dont know if you all seen these, but no matter, heres parts lists https://www.halls-cycles.com/Catalog/Halls-Cycles-Husqvarna.aspx

And little bit of topic.
I have 1980 wr front forks that im going to make as cr:s longer travel, ive looked parts list at my 80 model and it shows that only damper rods are different, longer. Has anybody made this?


P.s Ou and my 80 forks look same as yours and plastic was like in youre second photo
Ive looked also on some other age models and some of them shows different springs also.

T