TT250 FORK SEAL REPLACEMENT
The adjusting screws in the top of the forks contain O-rings.
These O-rings can be replaced if the caps are leaking.
TT250 Replacement Fork Oil Seals can be found here: Fork Seal RX3 RC3 TT250 - CSC Motorcycles
Tools required:
- Flathead Screwdriver
- Needle Nose Pliers
- 18mm Wrench
- Grease
- 19mm Wrench
- Small Screwdriver or Pick
- 22mm Socket
- Electrical Tape
- 37mm Fork Seal Tool
- Measuring Cup
The o-ring replacement can be done with the fork left installed, but is often easier to service when removed.
The fork cap can be unscrewed with a 22mm socket rotating counter-clockwise. (Pro-tip: loosen the cap while still install on motorcycle and keep hand tight)
The bottom of the cap can be accessed by sliding down the gold tube.
18mm and 19mm wrenches are used to release the locking nut under the cap.
The cap and needle can then be removed from the tube.
Remove the needle and cap from the tube.
Turn the fork upside down and drain the oil.
Gently remove the dust seal with a small screwdriver.
Remove the retaining clip with a small screwdriver.
Pull the tube out of the fork leg.
A vice is helpful in holding the fork leg.
Remove the small retaining ring using your fingers.
Remove the large retaining ring with your fingers.
Remove the washer.
Remove the oil seal.
Remove the dust seal.
This is the order of internal parts.
Clean the end of the tube of all oil residue.
Temporarily wrap the end of the tube in electrical tape. This will protect the new oil seal from being cut when installing it.
Install the dust seal.
Next, install the oil seal.
***Note that the larger spring is pointing away from the tube.
Install the washer.
Remove the tape.
Install the large retaining ring.
Install the small retaining ring.
Slide the fork leg over the tube.
Use 37mm fork seal tool to push in the seal. (***Note: using a screwdriver will damage the seal).
Install the retaining clip.
Securely fasten clip by pushing with a screwdriver.
Push in the dust seal.
The screwdriver handle can be used to safely tap in the dust seal.
Measure 9 oz (250cc) of new fork oil.
Slowly pour oil into the fork leg.
Insert the need and cap assembly.
Use 18mm and 19mm to secure locking nut.
Use 22mm socket to tighten the cap. Finish complete tightening after installing the fork on the motorcycle.