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Old 01-28-2017, 07:36 PM   #1
Prosie
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Default Need Help Rebuilding Forks

I have an '85 KLR 250 that I am rebuilding using a '90 parts bike.

I went to replace leaking oil seals and discovered stone nicks in the 85's forks. The 90's forks are smooth, but the bushings are shot.

I need to keep the damper rod from spinning so I can break loose the allen bolt at the bottom of the forks. As best as I can tell, the front axle nut (22mm) on the axle, a 22mm socket, and few extension make a good fit on the damper rod.

The problem is when I hold the damper rod with the 22mm nut & extensions and try to loosed the allen bolt the torque just loosens the nut on axle.

I figure either someone knows another way, or I need to get someone to weld a 22mm nut onto a T-handle.

Thoughts? This is my first time asking for help. I have found diligent searching has answered all my previous questions

Thanks, Prosie [ = Peter + Rosie: father/daughter KLR 250 riders & adventurers]
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Old 01-28-2017, 09:57 PM   #2
NVGTI
 
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Default Re: Need Help Rebuilding Forks

Try using two nuts and a washer between. Tighten the two nuts together and then try to use that to hold the inside of the damper rod.
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Old 02-06-2017, 03:05 PM   #3
littlejon
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Default Re: Need Help Rebuilding Forks

you might try 7/8 nuts on all thread and file them down just a little to 22mm. (a belt sander, or grinder would be quick)

Use JB weld, if two nuts wont tighten together enough.

Last edited by littlejon; 02-06-2017 at 03:08 PM.
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Old 02-13-2017, 10:15 AM   #4
Goofaroo
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Default Re: Need Help Rebuilding Forks

Use an impact wrench on the bolt on the bottom of the forks and it will pop right out. Use it again to reinstall but be careful not to over tighten. Then check it with a wrench. No special tools required to service these forks.
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Old 05-22-2017, 09:31 AM   #5
thecrimsonking
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Default Re: Need Help Rebuilding Forks

Hi I did that job last week, and I used the front wheel bolt to hold down whats inside the fork.
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