1986 200x Fork Rebuild

[PRIMETHIOUS]

I have a set of 1986 200X forks I'm rebuilding. I read through the forum and thought I had the proceedure. I cut off the damaged boots. I drained the forks, and removed the bottom bolt. I removed the top nut and both springs and washer. The bottom half of the fork now moves freely, but does not come off the tube. I have the forks mounted to the triple trees minus bike. I pulled at them quickly and and all I get is a firm clang. Any help would be much appreciated.

[Dirtcrasher]

Sounds like you forgot the clip that holds the seal, washer and spacer in place. It's at the top of the lower tube, under dirt and oil....

[PRIMETHIOUS]

Thanks! Is there a good way to remove the dust cover without destroying it or do I need abother on regardless?

[smvorndran]

A thin screwdriver or putty knife pops them loose. Those aren't usually in there very tight.

smvorndran

[Dirtcrasher]

If your gonna keep the 200X get new OEM seals and wiper seals and if any of the internal bushings have worn off the coating, replace those too.

If the bushings are very worn on just one side, you may have a bent tube....