toemoss Posted November 13, 2013 Report Share Posted November 13, 2013 Help please anyone. My project '93 tyz 250 is moving along, but I cant get the forks apart I loosened the allen bolt and was able to remove seals and the fork guide, bought new seals installed them but I could never get the allen bolt out when I was cleaning them and now can't get the fork tubes to tighten back up. I have no manual so if any one has a helpfull ideas I'm all ears. Quote Link to comment Share on other sites More sharing options...
lineaway Posted November 13, 2013 Report Share Posted November 13, 2013 The bolt should have come out. Trouble is were it stuck. You have the springs and cap back in? You might get lucky holding the bolt straight while someone else tries to guide it onto the bolt. Did the bolts stick on both forks. I would be worried that the aluminum cup on the end of the rod would some how not line up. Quote Link to comment Share on other sites More sharing options...
lineaway Posted November 13, 2013 Report Share Posted November 13, 2013 Just read it again this morning. Did you use just an allen wrench or an air gun? Quote Link to comment Share on other sites More sharing options...
toemoss Posted November 13, 2013 Author Report Share Posted November 13, 2013 I used an air ratchet and yes they are both stuck, I tried tightening the bolts with the springs and caps back in and without. Once the bolts were loosened up I was able to get the seals out but not the tubes or rods. I saw a bolg that shows a square tool inserted into the tube over the rod and there is a square opening at the base of the compression rod. I hate to take them to a shop as I have rebuilt many sets of old school and modern forks, these just have me scratching my noggin a bit. Quote Link to comment Share on other sites More sharing options...
lineaway Posted November 13, 2013 Report Share Posted November 13, 2013 I know the tool you are talking about, but never had needed it. I`ve never seen the bolts not come out as long as there was spring pressure. Quote Link to comment Share on other sites More sharing options...
toemoss Posted November 13, 2013 Author Report Share Posted November 13, 2013 My worry isn't getting the bolts out I would like them to tighten the upper tube so I can refill and ride. I'll retry tonight with the springs and caps, if that doesn't work I'll bring one to my workplace and fab something up to hold the inners. Quote Link to comment Share on other sites More sharing options...
woody Posted November 13, 2013 Report Share Posted November 13, 2013 I'm lost trying to understand what you've done You only loosened the allen bolts, you weren't able to remove them completely - which means you can't remove the tubes? But you managed to remove the seals with the fork tubes still in the legs? You removed the fork caps? If you unscrew the fork caps from the tube, they are still attached to the top of the damper rod and until you unscrew them from the damper rod you can't remove the springs. The usual process to fit new seals is to pull the tube completely out of the leg, so I don't know how you've removed and replaced the seals with the tube still in the leg.... Also, the allen bolts at the bottom of the leg house the damping adjuster which is a small brass screw head needle that screws through the allen bolt and into the bottom of the damper rod to control oil flow. If this isn't screwed right in before you use and allen key, you can damage the screw adjuster. If you don't have the tool to lock the fork internals the only way to remove the allen bolt is to use the spring pressure to stop the internals spinning. With the cap and spring fitted put the leg into the vice, then use a ratchet strap or something and compress the fork as much as you can, then see if the spring pressure will allow you to hand tighten the bolt until it just bites. If so, see if it will let you unscrew all the way. It should unless they were forced home and cross threaded or suchlike. The link below is to some instructions I put on some time ago for someone else asking for info on how to change the seals in a TYZ. http://www.trialscentral.com/forums/topic/27478-tyz-250-fork-seal-replacement/page__hl__%2Btyz+%2Bfork+%2Bseal Quote Link to comment Share on other sites More sharing options...
toemoss Posted November 14, 2013 Author Report Share Posted November 14, 2013 Woody I read your instruction only after I had loosened the allen bolt, Yes I was able to pop the seals out by pulling on thee fork tube but they will not come out all the way, almost like they are caught on the bottom fork guide. I removed the cap and springs, tonight my boy had H2O playoffs so I didn't get a chance to reassemble with the springs and caps and compress like you mentioned. This is not my first fork rodeo I didn't know that they were a cartridge type when I started disassembling them .Thanks for all the info Quote Link to comment Share on other sites More sharing options...
toemoss Posted November 14, 2013 Author Report Share Posted November 14, 2013 Woody after re-reading your original post that I found after searching this forum I took your advice from your last reply and cinched them down with a tiedown strap an presto they all came apart thanks for that last bit of knowledge.. now if I can just get my finger to quit bleeding I'll be fine. Hope all is good in the UK it's sunny and 95 in San Diego Quote Link to comment Share on other sites More sharing options...
Recommended Posts
Join the conversation
You can post now and register later. If you have an account, sign in now to post with your account.