Removing USD Fork Bottoms

[shandawg]

Just got the ZXR 250 back together properly - new motor, frame, discs, exhaust etc etc

Tightening up the cap screws that lock the front axle in place and..BANG! the whole piece which locks the axle on snaps right through

I have a spare set of forks, but want to use my nice freshly rebuilt ones by swappin the bottom of the spare, but I don't quite know how to do it without having to pull the forks right apart

Anyone out there with this kind of experience?

[curious george]

You need an easy out!
Drill the correct sized hole through the bolt, and use the reversed threaded 'easy out' to remove.
It's piss easy, but also easy to stuff up.
I'm in Devonport if you need someone to do it
PM me

[shandawg]

Thanks for the tip, but unfortunately it's the fork bottom that broke, not the bolt

I need to swap the whole fork bottom

[curious george]

Whoops, I stand corrected.
It is possible, but you need to disasemble the whole lot anyway.
I have been told to take them to someone like Tjebbie Bruin, or some specialist who will stand a better chance than most.
Better luck next time.

[kerryg]

Just got the ZXR 250 back together properly - new motor, frame, discs, exhaust etc etc

Tightening up the cap screws that lock the front axle in place and..BANG! the whole piece which locks the axle on snaps right through

I have a spare set of forks, but want to use my nice freshly rebuilt ones by swappin the bottom of the spare, but I don't quite know how to do it without having to pull the forks right apart

Anyone out there with this kind of experience?

Talk to Craig at Colemans (he's their suspension guy). He's a good bloke too!