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MX, SX & Off-Road Discussions
Dirt Bike Mods & Maintenance
Strange looking fork cap on a -97 CR250
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[QUOTE="mxneagle, post: 126332, member: 21267"] The '97 CR show forks used caps that threaded onto the cartridge tube and then the outside threaded into the fork leg. disassembly: 1. use a 32mm socket to remove the cap from the outer fork tube. 2. loosen the small grub screw (set screw) enough to clear the threads on the cartridge tube. If its your first one just remove it altogether. 3. use a very big adjustable wrench to hold the cartridge tube by the flats. The wider the jaws the better. Be careful if you decide to clamp the cartridge tube flats in a vice. It's possible to crush the tube! 4. Loosen the fork cap from the cartridge tube with a 32mm socket. It's locktite'd so it takes some doing and the sounds it makes comming loose will make you cringe. 5. before removing the damping rod from the cartridge use a wire wheel to clean (kind of burnish) the thread on the end. This is so the seal inside the cartridge tube is not damaged. 6. Remove the damping rod. 7. Clean the parts. Assembly 1. Insert the damping rod. 2. fill the cartridge with oil to the step in the tube. 3. pump the rod to bleed the air from the system 4. fill the cartride with oil to ~5mm above the step 5. insert the cap assembly (this takes a bit of force but can be done by hand) and thread the cap onto the cartridge and tighten. 6. insert and tighten the grub screw 7. pump the cartridge rod to full stroke. You'll hear the oil blow off into the top of the cartridge. 8. empty the excess oil from the top of the cartridge. 9. reinstall the cartridge into the fork leg. [/QUOTE]
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MX, SX & Off-Road Discussions
Dirt Bike Mods & Maintenance
Strange looking fork cap on a -97 CR250
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