1986 Honda ATC 250R front forks rebuild

[Marty]

I am seriously thinking about rebuilding front forks from my 1986 ATC 250R, I have new OEM seals and boots ready.
But I just want to know if it is a very difficult job to do? What kind of oil to use and how much? Do I need special tools for the job? And are those bottom bolts on the fork legs hard to come out? Do I need a pneumatic rachet to get those off?

[Dirtcrasher]

It's easy. DO NOT remove the springs and attack the lower bolt 1st, might be a 6 or 8mm allen bolt.

If it spins, you will need an impact.

Clean it all SPOTLESS (brushes for cleaning oil furnaces are great for this) just hit up your local HVAC or industrial park.

Reassemble, loctite that lower allen bolt and then you will need a tool to get the bushing back in as well as the oil and dust seals. PVC etc (think outside the box) to get the bushing/seal in. I also use a ziplock bag on the top of the tube and grease it, the slide the seal over it; No damage!

It's chicken, more dirty if anything but you will need a few tools.

Your old fluid will be grey/black and spotless.

EDIT, Make SURE you follow the manual and that the fork tubes are 100% straight; As well as the bushing still having the coating on them.