Honda CR250R 2004 Owner's Manual page 66

Fork Disassembly
Remove the fork as described in Fork Oil Change (pages
55 — 56).
Clean the fork assembly, especially the sliding surface
of the fork slider and bottom of the slider around the
center bolt before disassembling the fork.
CAUTION:
•
Be careful not to scratch the slider and not to
damage the dust seal.
Measure the length between the axle holder and outer
tube and record it before disassembling the fork.
1
(1) LENGTH
Hold the outer tube, remove the fork damper from the
outer tube using a special tool and slide the outer tube
down to the dust seal on the axle holder.
3
(1) FORK DAMPER (2) OUTER TUBE
(3) LOCK NUT WRENCH
Pour the fork oil from the outer tube.
Pour the fork oil from the oil hole of the fork damper.
(1) OUTER TUBE
Temporarily install the fork damper to the outer tube.
Set the lower end (axle holder) of the slider in a vise
with a piece of wood or soft jaws to avoid to damage.
CAUTION:
•
Do not overtighten the axle holder.
Loosen the center bolt.
1
2
2
(1) CENTER BOLT
Push out the fork center bolt from the axle holder of the
slider by pushing the fork damper.
Apply pressure to the fork damper and insert a special
tool or mechanic's stopper tool (see below) between
the axle holder and lock nut.
Hold the lock nut and remove the fork center bolt from
the fork damper.
CAUTION:
•
(2) OIL HOLE
1 (1) CENTER BOLT
(3) STOPPER TOOL
Make the mechanic's stopper tool out of a thin piece of
steel (1.0 mm thick) as shown if you do not have the
special tool.
(2) AXLE HOLDER
Do not remove the lock nut from the fork damper
piston rod. If lock nut is removed, piston rod falls in
the fork damper and you can not reassemble the
fork damper.
3
4
2
(2) LOCK NUT
(4) AXLE HOLDER
55 mm
25 mm
R7.55
–7.6 mm
1
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