How to disassemble the front forks – Honda CBR250R MC19

So at this point you have removed the forks from your Honda CBR250R MC19 and now it’s time to disassemble and reassess them.

Here is how to disassemble and assess the front forks on a Honda CBR250R MC19 motorcycle - looking at the bushings, springs, seals and chrome stanchion or slider. This may help you if you have a CBR250RR MC22 or a MC14 as well.

There should be a few hundred ml of fork oil inside each leg that we can drain out a couple of different ways – there’s a drain bolt on the fork leg (6x8mm bolt, part number 92000-06008-0A with copper washer 90543-273-000):

Here is how to disassemble and assess the front forks on a Honda CBR250R MC19 motorcycle - looking at the bushings, springs, seals and chrome stanchion or slider. This may help you if you have a CBR250RR MC22 or a MC14 as well.

This takes a 10mm socket or wrench:

Here is how to disassemble and assess the front forks on a Honda CBR250R MC19 motorcycle - looking at the bushings, springs, seals and chrome stanchion or slider. This may help you if you have a CBR250RR MC22 or a MC14 as well.

The fork oil will leak out slowly until you compress the fork, where it’ll shoot out under perhaps more pressure than you might expect – don’t be pointing it at your face or anything you don’t want sprayed with oil!

Here is how to disassemble and assess the front forks on a Honda CBR250R MC19 motorcycle - looking at the bushings, springs, seals and chrome stanchion or slider. This may help you if you have a CBR250RR MC22 or a MC14 as well.

Another way of getting it all out is undoing the bolt at the bottom and compressing the forks to get most of it out. You can then leave it sitting above a bucket or similar to try and drain as much as possible out before doing further disassembly. Finally, you could just remove the top bolt as described below and pour the oil out that way along with the spacer/spring/washer. We prefer using the drain bolt or the bottom bolt as we’re disinclined to fish around in fork oil for components, but it’s up to you.

Either way, if you haven’t already undone the bottom bolt (part number 90116-KV3-701 with an 8mm copper washer 90544-283-000) remove it now with a 6mm hex long socket:

Here is how to disassemble and assess the front forks on a Honda CBR250R MC19 motorcycle - looking at the bushings, springs, seals and chrome stanchion or slider. This may help you if you have a CBR250RR MC22 or a MC14 as well.

Here is how to disassemble and assess the front forks on a Honda CBR250R MC19 motorcycle - looking at the bushings, springs, seals and chrome stanchion or slider. This may help you if you have a CBR250RR MC22 or a MC14 as well.

If you loosened it slightly when the forks were in the bike it shouldn’t be hard to remove now. You can now remove the top shock bolt – be careful as this is under some spring tension so push down over the bolt as you loosen it to stop it from popping out… and needless to say don’t put your face etc. over it when you’re undoing it. 17mm hex socket:

Here is how to disassemble and assess the front forks on a Honda CBR250R MC19 motorcycle - looking at the bushings, springs, seals and chrome stanchion or slider. This may help you if you have a CBR250RR MC22 or a MC14 as well.

Beneath that you will find a metal spacer (part number 51402-ML7-691, available from Partzilla – also used on the 1987 VFR700F2 it would seem):

Here is how to disassemble and assess the front forks on a Honda CBR250R MC19 motorcycle - looking at the bushings, springs, seals and chrome stanchion or slider. This may help you if you have a CBR250RR MC22 or a MC14 as well.

You can now remove the spacer, the washer that sits between the spacer (part number 51403-ME4-003, Partzilla) and the spring (part number 51401-KY1-003):

Here is how to disassemble and assess the front forks on a Honda CBR250R MC19 motorcycle - looking at the bushings, springs, seals and chrome stanchion or slider. This may help you if you have a CBR250RR MC22 or a MC14 as well.

Here is how to disassemble and assess the front forks on a Honda CBR250R MC19 motorcycle - looking at the bushings, springs, seals and chrome stanchion or slider. This may help you if you have a CBR250RR MC22 or a MC14 as well.

Now turn your attention to the dust seals (part number 91254-ML7-003, eBay AU):

Here is how to disassemble and assess the front forks on a Honda CBR250R MC19 motorcycle - looking at the bushings, springs, seals and chrome stanchion or slider. This may help you if you have a CBR250RR MC22 or a MC14 as well.

They simply pry up with a pick or similar tool – be careful not to scratch the fork lower or chrome stanchion:

Here is how to disassemble and assess the front forks on a Honda CBR250R MC19 motorcycle - looking at the bushings, springs, seals and chrome stanchion or slider. This may help you if you have a CBR250RR MC22 or a MC14 as well.

Below this you will see the top of the fork seal and a snap ring (part number 51477-KR6-003, Partzilla) – we need to pry out the ring before we can remove the fork seal:

Here is how to disassemble and assess the front forks on a Honda CBR250R MC19 motorcycle - looking at the bushings, springs, seals and chrome stanchion or slider. This may help you if you have a CBR250RR MC22 or a MC14 as well.

Pry it out with a pick or similar tool – be careful not to mar the soft aluminium fork lower:

Here is how to disassemble and assess the front forks on a Honda CBR250R MC19 motorcycle - looking at the bushings, springs, seals and chrome stanchion or slider. This may help you if you have a CBR250RR MC22 or a MC14 as well.

Now that the snap ring is removed you can separate the two fork parts – grab each with one hand and pull them apart like a slide hammer, video below:

The bushings should now be visible on the end of the fork tube:

Here is how to disassemble and assess the front forks on a Honda CBR250R MC19 motorcycle - looking at the bushings, springs, seals and chrome stanchion or slider. This may help you if you have a CBR250RR MC22 or a MC14 as well.

Left to right – fork oil seal (51490-ML7-305), steel back up ring (51412-461-003, eBay AU), guide bushing (51414-MN4-003, eBay AU), fork pipe bushing (grey, 51415-MN4-003, eBay AU) and the damper rod (51440-KY1-003) visible poking out the bottom on the right. Remove all of the parts from the chrome stanchion (51410-KY1-003) except for the fork pipe bushing:

Here is how to disassemble and assess the front forks on a Honda CBR250R MC19 motorcycle - looking at the bushings, springs, seals and chrome stanchion or slider. This may help you if you have a CBR250RR MC22 or a MC14 as well.

There’s an oil lock piece (51432-MJ6-003, eBay AU) at the bottom of the fork lower on the inside – it hasn’t come out any of the times that we have cleaned MC19 forks so you may well not ever see it. Use white spirits (e.g. methylated spirits) to thoroughly clean all of the components and let them dry. Make sure to do the inside of the chrome fork stanchion and the inside of the fork lower (right 51421-KY1-003ZA, left 51521-KY1-003ZA) as well. Now it’s time to check the components.

Leave a Comment

Your email address will not be published. Required fields are marked *

Scroll to Top