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Old 08-17-2006, 08:37 PM
KxRacer411's Avatar
Beginner Class
Join Date: Jun 2006
Last Online: 08-18-2006 01:29 PM
Location: Lincoln, NE
Posts: 15
Unhappy 2005 yz250f forks...


Hey, I am trying to help a friend with fork seals, but we can't seem to figure out how to get the top and bottom apart. We got the top off and all the fluid drained, but I think there is a special tool needed maybe. You can see some threads, but I don't know where to unscrew from? Anyone have a service manual they can scan for me? I also need to know how much fluid to put in. Thanks! Mike
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Old 09-12-2006, 09:09 PM
cr2crf's Avatar
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Join Date: Jun 2003
Last Online: 09-13-2006 12:16 AM
Location: California
Posts: 8
Default Re: 2005 yz250f forks...

Undoing the top cap allows you to drain the outer tube oil. Once that is done you must put it back on and flip the fork over and undo the rebound damping bolt from the bottom. Once that is done, you must compress the fork so that the rebound damping rod comes through the bottom of the fork and then slide a 12mm open end wrench under the jam nut to hold the damping rod and jam nut end out of the fork end. Now use a 17mm openend wrench on the jam nut and I think a 22mm on the rebound damping bolt. Unloosen the bolt from the nut. Remove the rebound bolt and the thin adjusting tube that is inside the damping rod. Release the damping rod from the 12mm wrench by compressing the fork again. Now flip it back over, take the top cap off and the entire insides will come out. Now you can remove the dust seal, snap ring, and oil seal. When putting on the new seal, I use electricians tape to cover up the sharp edges of the fork tube. Cover the electricians tape with grease, carefully slide the seal on. Then put the bushings on and reassemble in reverse order.
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Old 09-12-2006, 09:30 PM
Florida 393's Avatar
Semper Fidelis
Join Date: Dec 2002
Last Online: 11-12-2018 05:52 AM
Location: Barrineau Park, FL
Posts: 7,303
Usflag Re: 2005 yz250f forks...

That is an excellent description of the procedure. You may wnat to go to an on-line parts fische for a diagram to go with his narrative.

BTW, welcome to ATM, please stick around for a while. Let us know if his post helps you out too.

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