Everything's Clean right? If not, Brake Cleaner (No Residue) and cleanup until happy. Then it's time to Put back together!
Put the Upper tube Into the Lower Tube. DEFY GRAVITY IN THE PROCESS. MY GARAGE HAS A BLACK HOLE UNDER THE WORKBENCH!
Some Notes for reassembly. Service manual has section cutaway of this part, very helpful. My intent is just meant to help. DO NOT FORGET THE SLIDE METAL.
Just some help showing which edge of the oil seal goes down. If you mess this up then you have to take the bike apart the next day because you're an idiot that can't be bothered to pay attention during this step. You will then have to join me in an exclusive club of people that have installed the oil seal upside down. Plus you get to see my totally awesome fingers. Revel. Soak it in.
Put it all together!
Put the metal clip on top of the oil seal, seat it in the groove with the PVC install tool.
Put the Dust Seal on. Use the PVC install tool on it.
Use the 09920-03250 tool to insert the Damper assembly + that little spacer that goes on the bottom. Make sure it registers in the bottom of the bore where it needs to go. Important, double check here folks just in case.
Tighten up the bottom bolt as the service manual states, using the damper holding tool and a torque wrench.
Reinstall the Stone Guard.
Fill up the fork as needed now if you want, you can wait right before you put the spring in if you want.
Put the spring in.
Put the spring spacer (white plastic) on with the narrow item facing down, to register the spring correctly.
Space the 17mm nut from the top of the damper rod assy to 11mm. States it clearly in the service manual.
Replace the top nut, tighten as instructed in the manual.
Replace that little C-Clip.
Tighten that top nut (Has the preload and Damper adjuster on it) onto the 46mm Tube on the internal threads onto the large threads on the nut.
Put it all together. Torque everything as stated. Only weenies don't use torque wrenches. Real mean follow the service manual.
I'm assuming you know how to get the front wheel back in