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Does anyone have a rebuild manual for the front forks on the 250? I am sure I can work out how to dis-assemble them from the parts diagram, but instructions would make it easier. Thanks

So one leg apart, what a rusty mess. Is it possible to take the damper rod assembly apart? One end looks peined over and the other looks like it has been spot welded.

Got the other leg apart and the bottom end fell off, so not spot welded. Just very rusty! Lots of rust pitting to clean up, but assume it will not make too much difference to the function of the forks.

Thank you for posting your updates here. I'm following on behind with a recently acquired 125 H based bike (seemingly called the 125 T which is also a model name for a decades earlier model). I had one fork leg seized solid and used ZX1 lubricant to help me free up the fork leg cap bolt and then the damper assembly.

BTW we live about 20 miles apart, I'm near High Wycombe, Bucks, and I'd be happy to meet up if that suits.

Looking at the parts book and my video of taking the forks apart and I think this is the damper rod assembly:
If you know different, please let me know.

Finally back together. Best of 2 sets of fork legs used, hopefully I have the internals assembled correctly.