1997-2001 Honda CR250 Fork Maintenance Part 1: Disassembly

This is PART 1 of the step-by-step rebuild for 1998-2001 Showa 47mm suspension forks.

You can find Part 2: Inspection here, and Part 3: Installation here.

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…

1997 fork cap stripped threadsSo In ‘98, Honda changed the design to a fork cap that threads INTO the compression unit, then the compression unit threads into the fork tube.

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.

Tools You Will Need

I made everything easy for you, here’s a list of supplies on Amazon.com CLICK HERE

Tools you will need are:

*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.

Lets go!

1997-2001 Honda CR250 Front Suspension Fork Disassembly

Click Pictures To Enlarge
Step 1: Separate the fork cap from the fork tube1 Remvove the fork cap
Step 2: Drain the old oil2 drain the oil
Step 3: Re-thread the fork cap (hand tight)3 re thead fork cap
Step 4: Back out compression and rebound clickers4 back out compression and rebound clickers
Step 5: Unscrew center bolt5 unscrew center bolt
Step 6: Install fork rod stopper6 install fork rod stopper
Step 7: Unscrew center bolt from compression rod7 unscrew center bolt from compression rod
Step 8: Remove internal push rod8 remove internal push rod




Step 9: Remove compression unit (damper) from tube9 remove compression unit from tube
Step 10: Unscrew fork cap assembly10 unscrew fork cap assembly
Step 11: Remove fork cap assembly11 remove fork cap assembly
Step 12: Drain internal oil12 drain internal oil
Pump piston several times to evacuate internal oil13 pump piston seveal times to evacuate internal oil
Step 13: Remove the spring13 remove the spring
Step 14: Remove the dust seal14 remove the dust seal
Step 15: Remove lock ring15 remove lock ring
Step 16: Separate the slider tube from the outer tube16 Separate tubes

 

1997-01 Honda CR250 Front Fork Part 2: Inspection →Large-Final

 

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