left threaded plug in fork lower sliding tube

[flanker]

Hello all, Im dismantling the forks in my ducati monza 250 and I may be missing something but I don't know how to remove the left threaded plug in fork lower sliding tube. Is there a special tool or do I have to construct my own. The manual shows a t wrench but with no specifics... size shape etc... Any help would be appreciated!!! Thx Rob

[double diamond]

I made a tool to remove this threaded plug. I drilled a hole through the end of a discarded fork tube and cut a 5mm hex wrench to fit through the hole. Clamp the fork tube in a vise and turn the fork leg with the axle. Maybe heat the threaded area a little. The plug actually coms out pretty easily. You could probably make a T-handle do do the same thing but the fork tube tool was expedient and works well. Matt

[DBDBrian]

Hi Rob, Like Matt I made a couple of tools to dismantle the forks on my 200, I assume the 250 would be the same.
The L/H thread plug has a 5mm slot in the top face. The tool has a 21mm bore with a cross pin to enter the slot.
The other tool is to remove the aluminium spring covers,the pin slides in the sleeve.
I heated the lower end of the slider before removing the plug, and also heated the spring cover.
Hope this helps
Brian.

[flanker]

Thx guys! those tools look great! Rob

[narrow_monza]

Do you mean this plug?

I used a drag link socket from Amazon.

[flanker]

Yep that one! A drag socket? Ive never even heard of one, but it looks perfect. but now I'm wondering if there is any reason to even remove it??? any thoughts.

Is there a tool you fashioned to remove the small springs. Mine didn't come out and I assumed that crud was in there but on looking at the diagram maybe its held on by a circlip? Anyhow do I need to remove those?

Finally how about the non metal washers? on the bottom screw and the side screw. No one seems to stock them. Can I use ones from a hardware store? Thx tons rob

[narrow_monza]

Which springs? The rebound springs?

[flanker]

yep the smaller springs are they held in by a circlip?

[double diamond]

The topping springs aren't held in with a circlip. the OD of the spring is slightly larger than the ID of the fork tube to keep them in place so you have to push them out.
There's no reason to remove the slider plugs if you can get the fork tube cleaned out to your satisfaction without removing the plugs. This can be difficult if there's a lot of accumulated sludge in the bottom of the tube. Also, the plugs will rust if there is water in the tube. I've also seen forks where the balls in the damper valve get loose inside the fork and get pounded into the plug, leaving peen marks on the plug and the end of the fork tube. If you see no signs of rust or loose damper balls and you can clean out all the fork oil sludge, you may wish to save yourself the effor of removing the plugs. Matt

[narrow_monza]

One of my springs came out and the other stayed logged in the slider. I used a dowel to push it out.
Any reason to dismantle the valves where the 6 balls reside?

Thanks