250R Fork Rebuild issue/?

[3wheelrider]

I'm in the process of rebuilding my front forks/shock seals on my 85R (has 86R shocks) & hit a snag. -I'm unable to remove the lower bolt on the bottom leg. Bolt spins but but doesnt come out. I did put back in my springs/cap but the bolt/rod spin together. Tried allen wrench by hand & also 1/2" air impact gun on it. Both forks are doing the same thing...I know this has ocurred with many of you. I searched for an answer but cant find it. -Help please...

[barnett468]

hello;

here's just two of several options:

have someone sit forward on bike. pull the tubes down with a tie down so the springs put more pressure on the dapmer rod. try the air gun for a few seconds only. too much might cause damage.

if this does not work buy a damper rod holding tool. see link below.

http://www.repairmanual.com/product/3-8-in-drive-inner-damper-rod-holding-fork-tool-ds-tool25/

[3wheelrider]

Shocks are of course removed already. I did try to loosen the lower bolts when they where still on the bike -but not with someone on the ATC. No helper now either. I already had thought of putting some type spacer on top of the springs to compress/tension it more but didnt try it yet- not sure if it would help enough? Got no PVC right now & sure dont want to have to buy that tool right now- IF possible. I do wish I had it though! I did get the damn stuck snap rings out!!!!!Dont you just love the simple things that get complicated?/?

[3wheelrider]

El Camex- Isnt the removing the shocks from the bike the first step? Is the manual wrong? -not being a jerk really. Like I said -I did try loosening them when it was still mounted anyway.
Also, -Im not seeing how that tool works or inserts. And dont understand how your homemade deal works either. Never done shocks before so I dont know about this really. I guess If bad comes to worse -I'll remount it all & try & get someone to sit on it?>>& try again.

[barnett468]

Shocks are of course removed already. I did try to loosen the lower bolts when they where still on the bike -but not with someone on the ATC. No helper now either. I already had thought of putting some type spacer on top of the springs to compress/tension it more but didnt try it yet- not sure if it would help enough?Hello 3wheelrider;

nope preloading the springs likely won't be enough and can be dangerous.

i suggest you simply look in the personals section of your local newspaper and find an add that says female, weight 165 with "womanly" figure, but dieting. in my experience, this chick will weigh on the far side of 225. just ask her over for coffee and a half a side of beef then ask her if she has ever sat on an atv before.

[Jason125m]

I always make sure to crack everything loose while the forks are still installed on the bike. Goodluck!

[3wheelrider]

I SEE said the blind man. Nevermind-I see how it works...
Barnett: I didnt want to try the spacer deal anyway & cause the springs to compess to far anyway or do other harm!
I'll see about the homemade tool like you said- EL Camexican.
-Thank you guys

[3wheelrider]

First let’s call them forks, or I get confused. Basically the bolts you are trying to remove are screwed into something called a dampening rod. The rod is what keeps the bottom part of your fork from falling off when you do a wheelie. It is round and allows your upper and lower fork to spin in order to get your axel bolt lined up with the wheel hub.

So, basically the rod is turning with the screw you are trying to undo. It is likely there is some Loctite on it, so you need to break it free. As Barnett suggested USUALY the pressure of internal spring is enough to allow you to break the bolt free, but if not you need to hold the rod INTERNALY. You can do it with anything that will create enough resistance to brake the bolt free. The tool Barnett posted is optimal, especially if you plan to do this again someday, but as I suggested just tapering a wood handle with a grinder and jamming it into the rod might do it, but if the wood breaks in the hole this gets a whole lot more fun, so I suggest using a metal rod.

I will add a link in a moment that might help you with the whole job.
Thanks alot man!!

[DohcBikes]

Reinstall the springs and try again, possibly with the "extra weight" suggested above lol.

Careful not to cross thread those forks or caps on re-assembly,,,

[Dirtcrasher]

Nothing wrong with a broomstick, the lower leg in a soft jaw vice and a good impact gun with allen socket on there.

[jb2wheels]

You might try:

With an assembled fork (springs back in).
Put a socket on the top of the fork - just to protect the air valve.
Flipping the fork over.
While using the impact wrench on the bolt, "bounce" the fork. Compress it while zapping the bolt with the impact gun.
Also, when I use the impact for this, I use it in quick spurts - basically just blipping the trigger on and off instead of just holding it on. In theory, it should not matter because it's an impact gun. In practice, it works better for me.

I bought the tool way back in the 90s for my Katana. It was expensive and basically a steel cone and a super long 3/8" extension. The top of Katana damper did not have an internal hex - just round.
Does the 250R damper have an internal hex head? Would be easy to make a tool with some all-thread and a couple of bolts - if you know the size of the hex.

I've never used the broom handle, but sounds like a good idea and the price is right.

[3wheelrider]

As stated in 1st & 5th post -I did try to crack them loose before & after I started disassembly. I did reassemble & tried again-put some of my weight on it while blipping the trigger( I never held the trigger).- didnt work.
I will try the broomstick trick-Hey that ryhmes!
I was aware of what was happening as I stated in post #1 that "the bolt & rod are spinning together".- El Camexican thanks for the thread.

[shortline10]

Just bring them over Jimmy , ill have them off for you in a couple minuets :lol: .
Stubborn ones will get a little heat on the allen bolt and then the snap-on impact will do the rest .....





As stated in 1st & 5th post -I did try to crack them loose before & after I started disassembly. I did reassemble & tried again-put some of my weight on it while blipping the trigger( I never held the trigger).- didnt work.
I will try the broomstick trick-Hey that ryhmes!
I was aware of what was happening as I stated in post #1 that "the bolt & rod are spinning together".- El Camexican thanks for the thread.

[3wheelrider]

Just bring them over Jimmy , ill have them off for you in a couple minuets :lol: .
Stubborn ones will get a little heat on the allen bolt and then the snap-on impact will do the rest .....
Thanks alot Mike-might have to take you up on that if I dont manage.....I cant find a stick that fits in there.
I had thought about giving it some heat with the heat gun but didnt try it yet. I'll let you know-Thanks alot again Mike!

[shortline10]

I'll be in the shop all day tomorrow if you need help .




Thanks alot Mike-might have to take you up on that if I dont manage.....I cant find a stick that fits in there.
I had thought about giving it some heat with the heat gun but didnt try it yet. I'll let you know-Thanks alot again Mike!

[3wheelrider]

I'll be in the shop all day tomorrow if you need help .

Thanks man-I'll be there later on in the day-hopefully not too late

[shortline10]

Are we back together yet ?

[3wheelrider]

Yes!-Thanks again Mike. Got it back together. We'll see how long these seals work-At least if I have to redo it with OEM seals it will be a breeze next time!

UPDATE::: Was able to go by Mike's home & he did me a huge favor & removed them for me. The allen bolt threads apparently had *RED* Lock-tite applied to them by the P.O.!:mad:
It took direct flame/heat directly to the head of the allen bolt HEAD with a small PROPANE?? canister for a good 30-45 seconds each. Followed immediately with his HD Snap-On impact gun while I was pushing down on the lower leg. It would NOT come off without the flame/heat. This method really works if your bolt just spins but wont unthread because of Locktite on threads!- -Hope this helps others...
Thanks again to Mike-Shortline10. I was S.O.L withoutcha :lol: