250ES fork rebuild help!!

[hatc200x1]

I am currently rebuilding the forks on my 250ES. And I am having a horrible time. In the manual it says to "depress" the fork caps down so you then can remove the snap ring and then the fork cap will pop out. For the life of me I cannot get the fork cap depressed. I've soaked it for a few days, I tried heat, and I have been using a hammer and a punch.

Has anyone rebuilt 250ES forks and they ran into this issue and they found a solution? Thanks!!

P.S. I searched for a thread but couldn't find one in good detail.

[atc007]

Search results

http://www.3wheelerworld.com/search.php?searchid=8654369

[hatc200x1]

Link doesnt work. It says "sorry - no matches. Please try some different terms."....

Anyone else?

[250es AKA Sarge]

I just rebuilt mine not to long ago.
I had a little trouble.
I locked mine in a vice with some rags wrapped around it. I put continuous pressure down using a large punch.
It won't move much but enough to take pressure off the snap ring.
On one of them the up pressure was a bit stronger and I had my son continuously apply pressure in pulses.
It would spring back but we could get it to push down with the initial force applied.
Kind of creating on off on momentary release of pressure. I then used a good shop magnet to get the caps out. You will see a couple of o-rings 1 per side.
My springs did not try to shoot out.
It may be possible your forks are slightly compressed creating more pressure? It won't move much when it does but it will be enough to remove that snap ring. I cleaned mine out with kerosene and dried em out with a hair drier. The seals I had to pop using a floor jack and jacking against the frame of my truck. After removing snap rings of course. This was my first step before removing the upper caps. I added a bit more fluid when they went back together. I might add some PVC spacers in the future to firm him up. It will take a good amount of force to compress it. Did on mine. Give it hell. Be careful and good luck.

[250es AKA Sarge]

A broom handle may work to. Did not use a hammer! Large punch down force that was it. You might be able to put I smaller diameter socket under it have someone lean on it..releasing pressure. Removing the snap ring from the bottom as it would be upside down at that point.

[hatc200x1]

Thanks guys. Even with the fork bottums off is there always pressure on the caps from the springs?

[hatc200x1]

Never mind! Before I hadn't realized there was pressure on the cap even with the fork bottums off. I did get the snap rings out with a buddy helping me for 35 mins till we got the trick of digging them off then the second one came off super easily.

Thanks!!

Hope this thread has helps someone out in the future!