Ok. So I am rebuilding a set of forks for a buddy. They are off of a 2004 crf250x. They are showas and have never been rebuilt. I removed the oil, fork inners, springs, dust seal and retaining clip on the bottom of the fork. All that is left is the fork leg, outer fork, and inside the oil seal and the bushings. I have tried everything to get these things apart and nothing has worked. I am having the same problem on both of them too so that makes it even worse. I have soaked them in pb, heated them, pulled them apart like a slide hammer so many times I can't count and I even built a reverse press using a ratchet strap to see if they would pop. So far nothing and I am getting super fed up. I called my buddy that works at a motorcycle shop and he said there isnt an easy way to remedy the situation and insists that brute force and repetitive motion will eventually wear down the bushing inside until it is eventually small enough to pop out. I've read countless threads and done a multitude of searches without any success. Does anyone have any info that could possibly help get these damn things apart? [confused]
FORK LEG STUCK!
- Thread starter 2004xb12s
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go cytocis
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Not sure I understand the precise issue you're having, but many forks I've had apart are retained by a 'keeper collar' that must be removed before disassembly can occur; is this possibly your situation?
go cytocis
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Sounds like you're ready to put the forks down and take a lunch break. 
Haha im not even working on them right now im at my real work. I just am trying to problem solve while its on my mind. I work on bikes on the side as a hobby to pay for my hobby. I think the forks may be bent. You can't tell by looking at them but my buddy said he ran into a tree and it was hard enough to break the headlight
50dro
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You probably spoke to the owner's wife...It's a shame they weren't willing to give advice. I give advice even if it mean losing a sale at times, but that's just me...
I also know a manager at Millennium Cycle that I could get you in contact with. He's a dirt rider at heart too and might be able to help. Text me if you want his contact info.
I also know a manager at Millennium Cycle that I could get you in contact with. He's a dirt rider at heart too and might be able to help. Text me if you want his contact info.
I have talked to a few of my friends that work as motorcycle mechanics and all they can tell me is that they are probably bent. It was just dumb because she wouldn't even let me talk to the tech. I am not going to just drop parts off somewhere or recommend someone take their parts there if you can't even explain the work involved or the cost.
50-75 bucks a day is a small price to pay for a good reputation for helping people out. I found it comes back in good Karma points and good customer referrals.
If you still have to be that worried about your bottom line. It sounds like it's in YOUR best interest to try a new approach.
Instead of seeing your customers as dollar signs walking in the door, take the time to INVEST in your customer base like you've invested in your career. You can't have one without the other.
Yes, it can be a PITA, but do it GENUINELY and you will get it back (in your bottom line) in spades. EVERY big successful business you know does some type of gratis work. Ask yourself why.
I say that as a successful self employed shop owner for 20 years with a second successful shop location for 9 years. I retired at 40 years old.
Instead of seeing your customers as dollar signs walking in the door, take the time to INVEST in your customer base like you've invested in your career. You can't have one without the other.
Yes, it can be a PITA, but do it GENUINELY and you will get it back (in your bottom line) in spades. EVERY big successful business you know does some type of gratis work. Ask yourself why.
I say that as a successful self employed shop owner for 20 years with a second successful shop location for 9 years. I retired at 40 years old.
Nothing wrong with helping and giving advice and some freebie time, etc, but I also understand you can't do it for hours a day. I'd sure be upset if I lost $50 a day.
There's a shop up the street from me the guy is extremely good, I do most of my own work but had him rebuild my forks and he's mounted tires for me twice. Charged me fair price all times and has given me some advice and even some help(labor) for free when I was stuck, and I've recommended him to others several times. My father broke down at my house not long ago and I highly recommended the guy to my father and he had him do the repairs. He was so pleased with the work and the price that he now goes there instead of 'his guy". And this is an hour drive for him. The shop got over $1,000 worth of business in one visit from my father based on my recommendation, even though I've only spent about $300 worth of business there. It's nice to find a good shop(it's becoming more and more rare).
Wish I could help more with the OP issue, unfortunately I can't...
There's a shop up the street from me the guy is extremely good, I do most of my own work but had him rebuild my forks and he's mounted tires for me twice. Charged me fair price all times and has given me some advice and even some help(labor) for free when I was stuck, and I've recommended him to others several times. My father broke down at my house not long ago and I highly recommended the guy to my father and he had him do the repairs. He was so pleased with the work and the price that he now goes there instead of 'his guy". And this is an hour drive for him. The shop got over $1,000 worth of business in one visit from my father based on my recommendation, even though I've only spent about $300 worth of business there. It's nice to find a good shop(it's becoming more and more rare).
Wish I could help more with the OP issue, unfortunately I can't...
BuellyBagger
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I'm not either. I'm a commision painter... When our shop manager would leave for an appointment or go on vacation they had me righting estimates and dealing with customers for free for about a year with no plan of compensation. An estimate takes about 20 mins and so does a delivery so they're about the same as answering phone q's. I got fed up and told them i was either not doing it or would be paid per hour for the time the manager was unavailible plus for what ever i got done in that time. it worked... they right it off as "training" and i get paid win win. So no i dont blame a shop for their tech not answering questions, but i still ask sometimes when im desperate.
Yes, the tubes are probably bent so either keep beating them up, or go shopping. Heres a link to the exploded view, you can make sure theres no sneaky snap ring in there.
http://www.bikebandit.com/houseofmotorcycles/2004-honda-crf250r/o/m2263#sch407975
Sorry for the hijack 2004xb12s. I will defend myself over false accusations and I won't be goaded into any further argument, messing up your thread anymore.
I was the one giving the free advice, small repairs, and long diagnosis on the phone.
My Techs were paid WELL with a base salary plus profit sharing. Not flagging hours. If they chose to help ME out that way, it was by their own volition. I lead by example and some of them have moved on to be successful shop owners themselves. I'm very proud of that.
In other words anrkizm95 "You're doing it wrong".
so either keep beating them up, or go shopping. Heres a link to the exploded view, you can make sure theres no sneaky snap ring in there.http://www.bikebandit.com/houseofmotorcycles/2004-honda-crf250r/o/m2263#sch407975
Sorry for the hijack 2004xb12s. I will defend myself over false accusations and I won't be goaded into any further argument, messing up your thread anymore.
I was the one giving the free advice, small repairs, and long diagnosis on the phone.
My Techs were paid WELL with a base salary plus profit sharing. Not flagging hours. If they chose to help ME out that way, it was by their own volition. I lead by example and some of them have moved on to be successful shop owners themselves. I'm very proud of that.
In other words anrkizm95 "You're doing it wrong".
If you look at bushing 7 & 8 I believe this is where the issue is. The binding of these two worn bushings aren't allowing them to pass over eachother.
http://www.bikebandit.com/houseofmotorcycles/2004-honda-crf250x/o/m2265#sch312066
I will be trying to pry out that oil seal tonight and see if that will allow me to reach the bushings. Maybe I can slide a piece of sheet metal between them so they wont bind. IDK. I'm willing to try anything at this point. I took this job to help a friend but its coming back to bite me. I already told him the situation was looking grim [sad]
http://www.bikebandit.com/houseofmotorcycles/2004-honda-crf250x/o/m2265#sch312066
I will be trying to pry out that oil seal tonight and see if that will allow me to reach the bushings. Maybe I can slide a piece of sheet metal between them so they wont bind. IDK. I'm willing to try anything at this point. I took this job to help a friend but its coming back to bite me. I already told him the situation was looking grim [sad]
go cytocis
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Without pics, and given that these are not forks most folks on this forum will be familiar with, I'm having difficulty visualizing your description. However, some bushings I recall seeing are split & they sit in a smaller-diameter recessed piece of the fork leg. They can only be removed by prying them along the split seam to slide them out of the recess. They are accessed from the top of the fork; it sounds to me like you're trying to access them from the bottom(?).
As long as you have #13 out (and it sounds like you do). they should separate. You won't be able to get the slide bushings out with the forks together.
Do you have the little allen thats in the axle hole out? Might help?
Do you have the little allen thats in the axle hole out? Might help?
