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.

Related: 1997-2001 Honda CR250 Rear Wheel Bearings Change

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


Tools You Will Need:

  • 50mm fork cap wrench (‘98)
  • Compression rod stopper/holder
  • 47mm fork seal driver
  • 21mm socket
  • 32mm socket
  • 17mm box wrench
  • Needle nose pliers
  • Torque wrench
  • Breaker bar
  • Pry bar
  • Channel lock pliers
  • Level setting gauge
  • Hammer

The Parts You Will Need:

  • Fork oil
  • Bushings and O-rings

*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.

Let’s 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 the compression unit (damper) from the 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

If you have any questions or anything to add, please leave them in the comments or on our FaceBook page!

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

Keep Your ’97-’01 CR250 Running Right!

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