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Makotosun

Front forks help

  • Catpie
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Front forks help was created by Catpie

Trying to get the cap off the top from my xt250 , the manual states a circlip but I cannot see one , has anyone took these apart before . thanks  Trying to get the cap off the top from my xt250 , the manual states a circlip but I cannot see one , has anyone took these apart before . thanks     Tried to post pictures but not letting me post them.
Last edit: 06 Aug 2024 13:18 by Catpie. Reason: Picture
06 Aug 2024 13:14 #1

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  • MarkT
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Replied by MarkT on topic Front forks help

Top of pretty much every page has a notice about the photo posting issue which hopefully will get solved soon.  Right now you need to use a 3rd party like Imgur to host and then post link here.

I'm not a fan of the caps held by a ring...  most likely it's a wire ring and you'll have to push the cap down into the fork tube a little to see and remove it with a pick tool.
1963 YG1-T, 1965 MG1-T, Allstate 250, 1970 CT1b, 1971 R5, 1973 AT3MX, 1974 TS400L, 1975 RD350, 1976 DT175C, 1976 Husqvarna 250CR, 1981 DT175G, 1988 DT50, 1990 "Super" DT50, 1991 RT180, 2017 XT250
06 Aug 2024 13:34 #2

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Replied by Catpie on topic Front forks help

That is great help many thanks &  a soak in some penetrating oil & i will give it a go 
06 Aug 2024 13:40 #3

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Replied by MarkT on topic Front forks help

If the rubber caps are missing and/or water got in there, it can be a real bear to do that job.  Link with picture of clip www.partzilla.com/product/yamaha/3J2-23183-00-00

I've had the caps stuck tight, got them knocked down enough and the ring removed...  and then had to drill and tap center of cap and to use a slide hammer to remove the cap.  Not fun and caps might get ruined.
1963 YG1-T, 1965 MG1-T, Allstate 250, 1970 CT1b, 1971 R5, 1973 AT3MX, 1974 TS400L, 1975 RD350, 1976 DT175C, 1976 Husqvarna 250CR, 1981 DT175G, 1988 DT50, 1990 "Super" DT50, 1991 RT180, 2017 XT250
06 Aug 2024 13:52 #4

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Replied by Catpie on topic Front forks help

i need to do the seals & refill with oil as one is leaking , can i do this without taking the tops off ? 
06 Aug 2024 13:56 #5

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Replied by RT325 on topic Front forks help

If it's rusty under the rubber cap you might need to tap it down to get the wire ring visible to pick it out. They're a pain if rusty. Gotta be careful. Set the bike with front wheel suspended & Spring will be under tension of sorts so just tap it down & let it come back until it gives up & comes right out. I don't think the cap goes down far before touching a very slight step but enough to release the wire clip. We had bad cases of rust when used on the farm. A design that should never have been used in my opinion. Think dt175 had that too about the same years.
06 Aug 2024 13:56 #6

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Replied by darinm on topic Front forks help

It's a tough job alone, much easier if someone can push down on the cap while you remove the circlip. Alone, I've used a wood clamp and 1x1x4" piece of wood to push down the cap while removing the circlip.

You do need the caps removed to do seals.
1972 Yamaha CT2 175
1972 Suzuki TS185 Sierra
2000 Suzuki RM100
2009 Yamaha WR250R
2013 Yamaha XT250
2013 BMW F700GS

The following user(s) Liked this Post: MarkT
Last edit: 06 Aug 2024 13:59 by darinm.
06 Aug 2024 13:58 #7

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Replied by RT325 on topic Front forks help

Sorry think Mark & i are typing together again haha.
06 Aug 2024 13:58 #8

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Replied by Catpie on topic Front forks help

Definately a bit rusty hence the penetrating oil but if i can do the seals and refill without taking them out then that will save some headache.
06 Aug 2024 14:01 #9

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Replied by RT325 on topic Front forks help

On those by memory the handlebars go across the top of the forks, so in desperation you could remove the clip & then sit the bike on the floor for extra spring pressure pushing on the caps, even apply the front brake & push down/forward. The caps will pop up to the bars.
Be very careful but think i'm right.
Had those forks & clamps on my DT1 for a long time many years ago.
One thing i forgot, but Mark might've mentioned--"[loosen the top clamp]" as believe it or not its enough to stop the cap jumping up from its seated possition if still tightened fully.

www.partzilla.com/catalog/yamaha/motorcy...80/xt250g/front-fork
www.partzilla.com/catalog/yamaha/motorcy...1980/xt250g/steering
Last edit: 06 Aug 2024 16:15 by RT325.
06 Aug 2024 16:14 #10

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