Royal Enfield Continental GT 250 fork rebuild

Continuing the rebuild of the Continental GT250. rebuilding the forks.

[@davidforeman4137]

This is the info from my workshop manual, i couln't find out how to send the image to you so i hope this helps 1. Lubrication The oil level is determined by a small screw at the back of each sliding fork leg. First place the machine on the centre stand, thus allowing the forks to extend. To fill each fork leg to the correct level remove the plug screws from the fork bead and the oil level screws at the back of the sliding fork leg. Pour oil in at the top until it runs out at the level boles. Wait until oil has stopped running and replace level plugs and plug screws. Recommended grades of oil• are Castrolite, Mobiloil Arctic, Esso Extra 20W/30, D.P. Energol S.A.E. 20W, Shell X-100 20/20W or Havoline 20/20W. 8. "250 Trials (Fig. 5) A ·'Casquette" is not employed on this model but the fork head houses the speedometer. The main fork tubes screw into the steering bead and are secured to the fork crown by two clamp bolts. Fitted over the lower end of the main tube is the bottom tube made of high strength aluminium alloy with an integral lug which carries the wheel spindle. At the lower end of the main tube is a steel bush which is a close fit in the bore of the bottom tube. The upper end of the bottom tube carries a bronze bush which is a close fit over the outside diameter of the main tube. The bush is secured to the bottom tube by means of a threaded housing which contains an oil seal. A stud known as the .. spring stud" is fitted in the lower end of the bottom tube and a valve port is secured to the lower end of the main tube. As the fork operates oil is forced between the spring stud and the bore of the valve port forming a hydraulic damping system. A compression spring 21 in. long is fitted inside the main tube between the upper end of the spring stud and the upper end of the main tube. The lower end of the main tube and upper end of the bottom tube are protected by a cover secured to the fork crown. • If temperature is above 90"F (32"C) use one of the followina :-Castro! XL; Energol S.A.E. 30; Mobiloil A; Esso Extra 20W/30; Shell X-100 30; Havoline 30. SECTION OF FORK LEG .. 250 TRIAlS •• Flg.5 The fork is filled with a light oil (S.A.E. 20) to a point above the lower end of the spring so that the damper chamber .. B.. is always kept full of oil. Upward movement of the wheel spindle forces oil from the lower chamber .. A .. through the annular space between the spring stud and the bore of the main tube valve port into the damper chamber .. B." During thU stroke the pressure on the underside of the valve plate causes this to lift so that oil can also pass from .. A .. to .. B .. through the eight

[@Thebikemechanic948]

Perfect, thanks very much

[@jankool01]

Great - the forks have always been a mystery to me. Could you show in detail how you assemble the rest of the forks? Thanks.

[@Thebikemechanic948]

Yes I certainly will, this will be in the next episode of assembling all the frame

[@davidforeman4137]

The workshop manual that i have recomends several makes but all around 20w 30. I have the manual as images if any of it is of use to you

[@Thebikemechanic948]

Thanks for this, I do have some manuals but I can’t find any that suggest oils, so this could be a big help, if possible could you email it to. [e-mail]