Reassembling front fork - 2003 Yamaha YZ 250

Well put on engine stand remove front wheel then mark yokes and fork alignment with marker pen undo retaining clamps on yokes if your forks are upside down ones then undo top cover s then there should be a bolt that holds the inner leg to the fork sleeve once u have removed fork leg remove inner leg from sleeve then you will be able to see the retaining clip inside the sleeve remove this then using a large flat screwdriver get under rubber seal and prize out they are not always easy once done replace with new seal reassemble refill FORK OIL !!! THEN reassemble forks to bike job done

if there like most... remove the front axle and wheel and loosen the bottom fork support and then the top one slide out one shock at a time and replace the boot and reassemble the oil is inside the shock. if the top support is the oil fill for the shock then carefully slide out the shock and replace the oil fill cap bolt then replace the boot and reverse the process.

Where you inserted the handle bars into the bearing assembly on the frame there is a fork clamp you had to tighten to secure the handle bars and front fork. Loosen this and you should be able to disassemble the front end. While reassembling be sure the you line up the notches on the fork with the grooves in the bearing assembly and that the handle bars are properly aligned before tightening the fork clamp.

Refer to this site, www.bikebandit.com for an exploded view of the front forks. Basically you must have the seals in the slider (lower part) and the damper tube in the upper fork tube. Then slide the upper fork tube down into the lower and install the bolt in very end of the slider. Then install the spring and top plug or put it in the triple trees and intstall the top cap. You'll have to put the appropiate amount of the correct weight oil in the tubes. The amount depends on what kind of forks they are. Since they've been taken apart, use the "dry" (as compared to 'wet") amount of oil.

Good Luck
Steve

You should be able to do this job provided you have a way to get the bike off the ground. Lifting the bike off the ground enables the forks to extend all the way. This is necessary because the stock spring will be longer and stiffer requiring a bit of compression when reassembling the fork. You may need a tool or a helper to compress the spring while you thread the fork tube cap back into the top tube. There is a special tool that is made to assist with this. Whether or not you'll need this tool, I'm afraid I can't answer that with guaranteed accuracy. I know that I've serviced many front fork assemblies without any special tools. This information applies to the standard Hydro-Shock front end only, not the Springer front end.

First of all don't add oil, change it. to drain your oil you need to remove the air tube, remove the front wheel, loosen the allen screw on the bottom of the fork, unscrew the fork top, then remove the fork tube, and turn it over to drain(be careful internal parts of fork will come out)remove parts clean and inspect. Reassemble in reverse order,snug up the screw on bottom, fill top with correct oil qty,cap top, tighten bottom and finish reassembly.

If you ask this question YOU should not be doing it! but your *** on the seat not mine.
Remove ...........front wheel, front fender,top fork cap and loosen lower triple clamp bolts under head light cover, forks are now out!
Remove 6mm bolt at the bottom of the fork leg and drain oil,remove dust seal and wire clip, now remove the upper fork nut (the spring will jump out at you).Pull the leg and tube away from each other, the old seal will stay on the tube..clean and reassemble driving NEW seal down into place with wire clip.....refill with oil

remove the forks and apply some grease to the bearings. do not over tighten when you reassemble

Yep, drain the fork oil, raise the front wheel in the air, remove the front wheel and axle. The nut to remove the lower leg is at the bottom, hidden by the axle. If it still leaks after seal replacement your fork tubes and lower leg sliders are worn out. Reassemble and remove the top fork cap. Pour in the correct cc of fork oil and ride.

go here for a parts breakdown
remove your forks and there is a allen screw in the bottom to hold the forks together . when you reassemble make sure you put the corredt weight and amount of fork oil.
later paul