Author Topic: YZ250D forks  (Read 5719 times)

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Offline Digga

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YZ250D forks
« on: March 05, 2017, 05:49:49 pm »
Need some help getting my YZ250D forks apart. Anyone know what tool I need to find/buy or got a secret technique in getting the rod out? I have tried & tried but cannot get the bolt out of the rod   :'( :'( :'(
1977 Yamaha YZ250D, 1977 Yamaha YZ400D, 1980 Yamaha YZ125G

Offline 80-85 husky

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Re: YZ250D forks
« Reply #1 on: March 05, 2017, 07:30:19 pm »
rattle gun with the springs in and pushing down on the top nut. only way to get tight damper bolts out. Other than that, make a damper rod holder and try again.

Offline jimg1au

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Re: YZ250D forks
« Reply #2 on: March 05, 2017, 07:45:33 pm »
I did this exact method but used a battery drill and cut up Allen key worked well

Offline Digga

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Re: YZ250D forks
« Reply #3 on: March 06, 2017, 09:35:13 am »
Done the rattle gun, still won't budge  >:(

Looking inside the tubes, there doesn't appear to be a nut or socket to lock into/onto. Must be a special tool to hold the rod.
1977 Yamaha YZ250D, 1977 Yamaha YZ400D, 1980 Yamaha YZ125G

Offline 80-85 husky

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Re: YZ250D forks
« Reply #4 on: March 06, 2017, 11:02:49 am »
there is usually a small bar across the damper tube that  a slotted piece can lock onto. google them as you can buy them new. a long tube with a slot and tee on the top to hold it usually works. have you heated them up? someone may have used top of the shelf lock tight?   (they are out there)

Offline fred99999au

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Re: YZ250D forks
« Reply #5 on: March 06, 2017, 11:45:37 am »
You could try a broom handle up the tube, while applying pressure and using a rattle gun. Prolly a 2 man job though.

Offline Iain Cameron

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Re: YZ250D forks
« Reply #6 on: March 06, 2017, 07:07:20 pm »
I cant remember if its 12 or 13 or 14 mm but the top of the shaft has a crown on it Ive wedged a socket on a long extention shaft over the dome ( them when no one is looking belted it with a knock ometer . the socket it tight the use a allen key in a rattle gun . try soaking lower fork in WD40 for a few days in a bucket .
Yamaha tragic ; dt1, rt1, dt2, rt2, dt2mx , rt2mx , mx250, mx360,sc500, 74dt125, yzx125, yzc250, yzc400, yzd250, yzd400, yzh250, yzh80 , dt100 , xr75 ko xr80 03 , it175 82 . Not a member of any club

Offline Digga

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Re: YZ250D forks
« Reply #7 on: March 06, 2017, 08:01:50 pm »
Thx guys, going to give it another go later with everyone's advice, so fingers crossed
1977 Yamaha YZ250D, 1977 Yamaha YZ400D, 1980 Yamaha YZ125G

Offline fred99999au

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Re: YZ250D forks
« Reply #8 on: March 06, 2017, 08:44:27 pm »
From memory, my IT400D was like a double hex. I have a fine collection of bits of threaded rod with nuts of various sizes welded on for this exact purpose. Some are plumbing firrings which are soldered on, but they work.

Once you get one out, you can make a tool for the other.

Offline 80-85 husky

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Re: YZ250D forks
« Reply #9 on: March 06, 2017, 08:50:53 pm »
just did an old postie bike's fork oil change. 1 wack with the nylon hammer and they unscrewed by hand...sorry, just thought I had to pass it on.

Offline Slakewell

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Re: YZ250D forks
« Reply #10 on: March 07, 2017, 07:34:47 am »
Buy one meter of 20 x 20 RHS , cut a V into one end about 50mm long then close up in a vise. If you can, weld up the V and grind smooth , now push firm into fork and hold with a shifter.
Current bikes. KTM MC 250 77 Husky CR 360 77, Husky 82 420 Auto Bitsa XR 200 project. Dont need a pickle just need to ride my motorcickle

Offline Michael Moore

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Re: YZ250D forks
« Reply #11 on: March 07, 2017, 03:43:48 pm »
You could try a broom handle up the tube, while applying pressure and using a rattle gun. Prolly a 2 man job though.

That's the my next thing to try if the impact doesn't loosen it with just fork spring pressure.

Offline motomaniac

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Re: YZ250D forks
« Reply #12 on: March 07, 2017, 11:54:39 pm »
Buy one meter of 20 x 20 RHS , cut a V into one end about 50mm long then close up in a vise. If you can, weld up the V and grind smooth , now push firm into fork and hold with a shifter.

You can't push into the damper rods on the Ds they have a turned top with holes on the side.

Offline William Doe

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Re: YZ250D forks
« Reply #13 on: March 08, 2017, 07:22:29 am »
Drill the heads off the bolts 8mm drill bit, they are very soft steel and fit new bolts when reassembling .The rest of the bolt will just unscrew out of the damper rod once apart , I do this all the time , usually after some clown has buggered the hex head .
Its only old bike racing FFS get over yourselves





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