YZ250D forks

[Digga]

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   

[80-85 husky]

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.

[jimg1au]

I did this exact method but used a battery drill and cut up Allen key worked well

[Digga]

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.

[80-85 husky]

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)

[fred99999au]

You could try a broom handle up the tube, while applying pressure and using a rattle gun. Prolly a 2 man job though.

[Iain Cameron]

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 .

[Digga]

Thx guys, going to give it another go later with everyone's advice, so fingers crossed

[fred99999au]

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.

[80-85 husky]

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.

[Slakewell]

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.

[Michael Moore]

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.

[motomaniac]

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.

[William Doe]

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 .