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The TTR250 FAQ web pages -> TTR250 -> Repairs and maintenance -> Splitting the forks
Post Info TOPIC: Splitting the forks
spud351


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Splitting the forks
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I'm going to get my fork lowers powder coated so need to split the forks on my raid. As I don't want to get smashed in the face with anything under pressure what's the procedure to get the forks apart? Is it the large allen screw from underneath or do I go from the top. I don't want to strip the fork internals if I can help it, just seperate the fork lowers.

cheers SPud.

 



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Hi Spud

I got a mental block with forks and try and avoid them if Ican hmm

Does this guide help ? http://www.ttr250.com/TTR_renew_fork_seals.htm

I don't think the Raid forks can be that different to the OE in the pics.

Brian



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spud351


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Thats done the trick thx. By the smell I don't think the oil had ever been changed ever. bleh



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spud351 wrote:

By the smell I don't think the oil had ever been changed ever. bleh

 One of the reasons I don't like doing forks. I always seem to leave some oil in the fork leg to spill on my legs and feet as well - yuck no



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spud351


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Ok bad news, the allen screws in the bottom are seized solid very close to the point of the allen head being totally ruined trying to undue them. Has anyone any idea of what they bolt into and the feasibility of drilling them out? I could just forget it and paint the leg lowers but am keen to get them powdered the same as the frame.

One other thing. What does the little screw do? Is it for damping or something?



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Bad luck cry

Out of about 12 that I have done, I had one totally seized up. Both the screws and the legs are alloy and they almost weld to each other.

An air impact wrench usually moves the stubborn screws but I had to drill out the really badly seized one as I completely mullered the hex socket. I should have stopped and rebuilt the fork leg as it was because I now have one that isn't usable unless I just happen to come across another screw head.

Probably not what you wanted to hear hmm

Regarding the little screw, what number is it on the fiche please?

Brian

Fork leg fiche.jpg



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spud351


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Mmm, doesn't look to be on the diagram. 19,44 at the bottom of the leg is a little rubber cover. Under that is the hex head bolt, but in the middle of that bolt is a small screw perhaps M5?

Is not 17,42 the bolt you need to replace and I want to drill out?

 



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spud351 wrote:

Mmm, doesn't look to be on the diagram. 19,44 at the bottom of the leg is a little rubber cover. Under that is the hex head bolt, but in the middle of that bolt is a small screw perhaps M5?

Is not 17,42 the bolt you need to replace and I want to drill out?

 

Can't recall the screw but perhaps it is just a drain plug?

Yep - 17 or 42 is the part I mullered disbelief 



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spud351


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So you wrecked the head but what happened drilling it?



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spud351 wrote:

So you wrecked the head but what happened drilling it?

 I got it out but it is too damaged to put back in.



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spud351


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I take it from that they are NLA?



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Fork adjuster 001.jpg

 

Fork adjuster 002.jpg

I think you can see from the pics why I can't re-use mine disbelief

The screw you mention is an adjuster as mentioned in the item on the TTR250 FAQ on setting up your forks. That can be seen from the pics.

The part is available - part number 4PX-2316A-10-00 VALVE COMP. but if you phone MotoWard or Fowlers for a price my bet is that it will be over £50.

Brian

 



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spud351


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Oh no, now I see how it's made up. Even spraying loads of WD40 ain't gonna reach them threads. What a crap design.



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