I am in the process of rebuilding the front forks and ran into two issues that I need help with:

1. The cylinder will not come out of the fork after removing the 6mm bolt from the bottom. It has a metal clunk when I try to remove it.

2. The 6mm allen bolt just spins and spins and will not release from the inside of the fork.

Help on this would be appreciated.

It is usually not too difficult to get the Allen Head screws out of the bottom , but needs
help . I usually use an impact driver with a long Allen key , and compress the fork ,
using the spring tension to stop the inner damper rod spinning .
Once those are removed , undo the top cap and remove the spring and spacer .
Lastly the nut ( as Yamaha describes it ) on top of the lower slider unscrews .
I take off the dust cap , and use some slipjaws where the dust cap sits , as to leave any marks
concealed . Once nut is removed everything will separate .

Sometimes the Allen bolt is stubborn, I usually leave the the whole assembly together with the spring removing the bolt. Try using a electric impact gun while compressing the forks. This works for me.

If you have taken all the oil out remove the top nut on the upper fork and remove the spring and compress the fork, you should be able to see the damper rod, on my DT 250 1979 I managed to use a 16MM oil drain plug that fitted in to the top of the damper rod allowing you to remove the 6mm Allen blot and stop the damper rod from turning

If you remove seal holder 12 that also holds the top bush in you might be able to top the fork out against the underside of the damper to hold enough pressure on it to finish removing the allen screw. Not had mine in bits for--40 years lol.
www.partzilla.com/catalog/yamaha/motorcy...1969/dt1b/front-fork

& after that's undone a bit of an upward tap-pull, will pull out the top bush & fork tube with damper etc complete. Think i have a factory tool to lock onto the top of the damper via a long 3/8 drive T bar. Tool came with a selection off fittings for different fork dampers.

OK, still need help on getting the upper part of the fork loose from the bottom.

(Got allen screw out, Thank you for the advice)



Shouldn't items 4 & 5 (in the pic) fall out when I turn the cylinder upside down? Which then allows the upper fork to release....... stumped on this one.

I see you have the Allen screw out now--so,
Ok then. 4 is held into the bottom of the fork tube--stanchion--by circlip 3. But that has to come out of the bottom of the stanchion. Then the complete damper will come with it. but to get 'that far' you need to pull the stanchion out. So to do that you need to unscrew 12 then pull the stanchion & that will pull out top bush 10 complete with damper inside. 'Then' you probably have two options. One--remove the tapered piece on the bottom of the damper which would normally pull off, then damper should fall out the top but be careful of damper washers & stuff. Or pop that bottom circlip 3 & remove damper complete with 4 from the bottom. Sorry think i'm going in circles a bit but hope you get the idea. also to undo 12 i used to just grab it with emery cloth & big slip joint pliers, but wasn't worried about a few marks but if you're not keen on that idea then i don't know, maybe a couple of good quality hose clamps tightened then trapped in the vice at the clamp screws then turn the fork leg. Good luck--or '&' good management.

Try putting the oil drain screws back in and snug them up to hold the spinning things inside.

See the threads on the top of the fork lower #1?

Have you unscrewed the "seal holder" from the lower tube?