This is PART 1 of the step-by-step rebuild for 1998-2001 Showa 47mm suspension forks.
Full Step-By-Step Rebuild Guide Below the Video
This dirt bike is a 1997 Honda CR250. I would be rebuilding the original forks, but the rebound clickers broke off on both forks, and replacement fork cap assemblies are hard to find and way too expensive.
Instead, I found a set of 1998 forks on ebay for around $115 that I am going to show you how to rebuild.
The 1997 forks and the 1998 forks are the same, except for the way the fork cap assembly is connected to the fork compression unit and tube. The ‘97 fork has a cap the screws onto the OUTSIDE of the compression unit (damper), and uses a set screw to keep the cap in place.
This proved to be a problem for people because they would forget to tighten the set screw and strip out the fork tube… like I did…
So the only difference between a ‘97 and a ‘98-’01 fork is the fork cap assembly, other than that, everything is the same as far as disassembly, maintenance, and reassembly goes.
First things first, gather all the necessary tools.
I made everything easy for you, here’s a list of supplies on Amazon.com → CLICK HERE
Tools you will need are:
- 50mm fork cap wrench (‘98) (Link to Amazon)
- Compression rod stopper/holder (Link to Amazon)
- 21mm socket
- 32mm socket
- 17mm box wrench
- Needle nose pliers
- Torque wrench
- Breaker bar
- Pry bar
- Channel lock pliers
- Level setting gauge
- Fork oil (Link to Amazon)
- Bushings and O-rings (Link to Amazon)
- 47mm fork seal driver (Link to Amazon)
*You will need to know proper torque specifications and oil levels, click here to open this information in a new window.
Start by loosening the top bridge screws of the triple tree and loosen the fork cap in the tree. Just loosen, do not unscrew! Loosen the lower bridge screws and remove the fork.
1997-2001 Honda CR250 Front Suspension Fork Disassembly