Did I do something wrong?

About 10hrs of riding ago I put new seals and fluid into the forks of my 09 yz450. I inspected the bushings and they were fine with minimal wear. I put 5wt in the inner chamber and 10wt in the outer. Turned out the forks were really stiff and couldn't get the rebound right. So i tore them apart again to try a diff fork oil wt/ level. Once i opened it up all the bushings were worn out. Did i not assemble somthing right? I followed the manual for fluid amounts and re-assembly.

Were the forks being pinched together by the axle or did you make sure to align them when you put the wheel on?

I believe i tightend/torqued the pinch bolts first then tighten/torqued the axle bolt.

I believe i tightend/torqued the pinch bolts first then tighten/torqued the axle bolt.

Most likely your problem, if the forks weren't aligned then they will bind and wear out the bushings. You need to spin the axle in the fork lugs, or push the suspension up and down a few times with the pinch bolts loose to allow the forks to self-align, then tighten everything once the forks are parallel.

Well how can i tell if the forks are binding?

Unless it's really severe, you can't. But if you use the procedure KJ described, you'll know they are correctly aligned.

  1. Snug the axle nut to 10-15 ft/lb
  2. Tighten the left (brake) side pinch bolts
  3. Fully tighten the axle nut
  4. Take the bike off the stand and bounce the front suspension as fully as you can a few times to force the right side fork tube into a correct, properly aligned position on the axle.
  5. Tighten the right side pinch bolts

Unless it's really severe, you can't. But if you use the procedure KJ described, you'll know they are correctly aligned.

  1. Snug the axle nut to 10-15 ft/lb
  2. Tighten the left (brake) side pinch bolts
  3. Fully tighten the axle nut
  4. Take the bike off the stand and bounce the front suspension as fully as you can a few times to force the right side fork tube into a correct, properly aligned position on the axle.
  5. Tighten the right side pinch bolts

Before this process are the forks installed/torqued in the triple clamps?

Yes..

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