1983 250R Fork Rebuild Help

[JDeal]

Hello All,

I am wanting to rebuild the front forks on my '83 250R. Fork tube outer measurement is just shy of 35mm. I am in need of the upper and lower bushings. Is anyone aware of where I can find bushings?

[wonderboy]

Upper bushing is available from Honda still.

BUSH, GUIDE
51414-469-003

About $9, depending on where you order from. On-line parts sites will have better prices than the parts counter at your local shop (most likely).

FYI: The OEM fork seals are available for about $16 (I'd recommend OEM over aftermarket)

SEAL SET, FR. FORK
51490-KBH-305


I couldn't find a part number for the lower bushing on the fork tube.

[JDeal]

263685

Above is the diagram for 1983 250r forks per honda. They only show there being one bushing at the top. Even though there is a bottom bushing on the ones I have.

263686

The 1985 diagram shows the bottom bushing but doesn't have a part number designator. This diagram more closely resembles what I have except I have the air valve at the top. Is this just a mistake by honda?

[wonderboy]

They all have a bushing at the bottom of the fork tube (84/84 R, 85/86R, 350x) they just don't appear to sell it separately. 83/84R and 85/86R fork parts aren't interchangeable. The 83/84R forks are a smaller diameter than the 85/86R forks.

What condition is yours in? There is typically a greyish coating all over the bushing. It can be worn through a little bit and still be ok. If your bushing is copper colored all the way around uniformly, then it may be time to try to find a replacement.

[wonderboy]

For example -

Good Condition Bushings:
263691

Poor Condition Bushings:
263690

Here is the inspection process per the service manual for the 83 250R
263693


NOTE: my example pictures aren't entirely apples to apples comparison. The example of the "worn" bushings are just as an example. These are actually the upper bushings which are coated on the inside. The outside of the upper is always copper colored like that. BUT, as an example of what a worn lower could look like, it is representative.

[JDeal]

Per your direction, I inspected the bushings. The uppers appear to be almost brand new. The lowers have some copper showing through the teflon but its less than 1/4. Thank you for your direction and I will be replacing the seals and refilling the forks.