RGS Fork Install Question

[Rockitdoc]

So, I will go down in history as the 'high maintenance' forum member, but I'd rather not cock this up too badly, so here I go again....

The fork tubes are TIGHT in the yokes, yes?  I got the right one in, but the left one is stubborn even with some light oil and a wedgie:

I am reluctant to try to spread the yoke very much as it is cast AL.  Is this recommended, or is there another trick?  Banging on the bottom of the strut with a rubber mallet just compresses the spring after a while and the tube doesn't go any further.

Keep at it?  I am persistent, you know. 

Oh, and is installation off the frame a better way to get the top yoke into position?  This seems like the way the shop manual shows it done.

 

[Laverdalothar]

Scott,

try to mount it first without the screw in place. If this works better, check if the screw has a part in the middle where the threat is actually removed. It is a very, very tight fit as I think the first yokes were 38mm yokes bored out to 41,7mm, which means the slider is touching the screw (depending on how it was bored).

Also check there is no paint blocking the movement...

 

[Grant]

Take the first one back out.
Try the tight second one again.
If it slides in easier then it could be the yoke holes are not parallel (badly machined or bent yokes).
If it is still tight then try what Lothar says.

 

[Rockitdoc]

Scott,

try to mount it first without the screw in place.

This is the yoke that had the screw cut too close to the fork tube, so installing without the screw is not an option as the screw will not go in with the tube in place.  However, I got it in.  Sanded out a thin layer of paint that had got in there.  Now, for the top yoke.  This should be even more fun.  Two, at once. I'll get a bigger rubber hammer.