[rocketman]

My son has a 2004 250x, the front forks have been internally lowered by Boykin suspension in Modesto CA. He is now ready to raise the bike up and I thought someone out there may be looking to lower their 250x. there are no leaks, the forks work great he has finally grow into the bike and now prefered the hieght of mine. I am in northern CA if anyone is interested in a trade.
Dan

[Asmith]

Dan,

if they did the internal lowering correctly, it's easily reversible.

Can you find out if they re-machined the spring stop clip and used a spacer on the rebound rod?

If so, I can walk you through the process to restore it. 2 hours and no more than 4 1/2 beers...

[rocketman]

A.S. I will make a call and find out, I figured someone out there might want to take the easy way out. I may be taking you up on the walk through.

[rocketman]

Well it would appear that their phone number does not work any more. Bummer, another victim of a bad economy? How would i tell if if they re-machined the spring stop clip and used a spacer on the rebound rod? I know i called him once to ask how they lowered it and he said they use internal spacers. I am kinda hoping all i would have to do is remove those spacers??

[Asmith]

Well it would appear that their phone number does not work any more. Bummer, another victim of a bad economy? How would i tell if if they re-machined the spring stop clip and used a spacer on the rebound rod? I know i called him once to ask how they lowered it and he said they use internal spacers. I am kinda hoping all i would have to do is remove those spacers??

Correct. Remove spacer on the rebound rod and move the circlip back to the original groove for the spring stop.

Not a difficult job at all.

[rocketman]

Shoot! That may have to be on my list soon, I am still kinda hoping someone out there wants to lower thiers, the front end swap sure sounds easier

[rocketman]

Well its finally time to rebuild the forks on both our bikes (2004 250x) I took both sets of forks apart last night and found that they cut the springs on my sons bike (lucky for him i kept my stock ones) and i am still guessing some kind of spacer in the cartrige since it is still shorter than mine.
When I pull these apart tonight what an i looking for?
I will be doing them side by side so I imagine i can compair the two of them.
I am hoping this will be self explainitory*** "Remove spacer on the rebound rod and move the circlip back to the original groove for the spring stop."
Thanks for your input.

[Asmith]

The rebound rod ( the shaft that moves in and out ) has to be removed.

The trick: Removing and reinstalling without cutting the lower seal.

The solution: Putting one layer of clear, thin packing tape around the threads on the bottom of the rod after removing the nut. Lube the tape generously and push the rod through the seal. Rod then falls out through the top.

You should see a "spacer" under the midvalve stack (piston and valving on the top of the rebound rod.) Remove the spacer and re-install the rod.

The circlip for the big springs shouldn't need to be moved as they cut the springs shorter instead of just moving the circlip (lazy way of doing it...and more costly if you don't have spares laying around).

Good luck, call if you get hung up.

[rocketman]

Thanks Paul

[rocketman]

Paul, I have the piston rod out and it looks like some kind of spacer sleeve in the fork damper, it did not just fall out nor does it seem like it wants to come out. I have both mine and my sons apart and i can measure down the inside of the damper 21" before i hit any thing on mine and only 18" on my sons. So sound like 3" sleeve, also found fork springs cut 3.25".the spring on the fork cap assembly has not been cut. I am worried about damaging the inside of the damper if i put any thing else inside to try and push it out. Is there any kind of retainer the would hold this spacer in place? The service manual doesnt shoow much in regards to the damper assembly. any more sugestions would be great!
Thanks Dan

[rocketman]

Got it! (Special tool) I Ground two sides of a flat washer so it would fit sideways through the bottom hole were the damper rod comes through and then was able to flip it up against the back of the spacer and tap it out with a punch. It took three tries with different size washers and a bit of paitence to get it flipped up with out it just sliding back out the other end but finally I got them out. Looks like some heavy nylon or grey pvc type of product. What a pain Thanks for your input, as always a big help.
Dan