00KX250 Fork Disassembly Question

Joined
Feb 22, 2000
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#1
I'm dismantling my forks for the first time and I have run into a problem getting the cylinder valve assembly out of the bottom of the fork. I'm holding the fork in a vise at the base of the inner tube where the axle slides through, and I tried to unscrew it out but it's not coming out. I'm following the manual word for word(minus the special tools)and I'm wondering if the damper rod has to be held (because it's turning) or whatever, I just don't know. These are my first set of inverted forks I've worked on. Any help is appreciated.
 
Joined
Jun 17, 2000
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#2
the cartridge will have to be held to stop the turning or you can spin it out with an air impact

I haven`t seen a cartridge holder for the 2000 yet in any tool catalog , I made my own after I had one apart to measure it

before I had made the holder I spun the base valves out with a 1/2"dr impact using my nitrogen bottle to drive it
 
Joined
Jan 6, 2001
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#3
It sounds like the cartridge is turning. I'd suggest buying the tool. You can get them from Race-tech or Kawasaki. The other thing that you can try is to put your spring and cap back in and compress the fork to try to stop the cartridge from turning. While somebody else is compressing the fork you can try to loosen up the base valve. If you have an impact wrench that may also make it easier. I had the same problem and I bought the tool
 
Joined
Nov 17, 2000
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#4
I've done the same thing as KXKen. I left the bike assembled on the trailer, pulled the bleeds out of the top of the shocks, and using the straps, pulled the front end of the bike way way down. This binded the "whatever kind of guts are inside of the shocks" and the bottoms unscrewed right out. No problem.

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LaRider#20
 
Joined
Feb 22, 2000
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#5
So can you impact the base valve out first before you pull the cap ,spring, and rebound rod out without damaging anything? If you can, that would save some time next time.

Also, what exactly is the "special tool" holding? If I knew that I could find a way around it this time so I can build my own once I understand what's going on in there.

[This message has been edited by Colonel (edited 04-03-2001).]
 
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#6
Yes you should be able to pull it out without damaging anything. As far as the tool goes I've got a 99KX so I don't know if the tool is exactly the same or not my Kawasaki part # is 57001-1413. If you have a service manual check and see if it's the same #. If you pull out your spring and shine a flashlight down into the tube you will see that the cartridge has 4 slots on it. The tool is a long tube with 4 (sort of) fingers that go into the 4 slots in the cartridge to hold it while you turn the base valve. Hopefully this will help.
 
Joined
Mar 19, 2001
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#7
I've pulled Kayaba forks apart a million time and never used a special tool to hold the cartridge. I've always used an impact to get them apart. I hate for you to have to buy a tool you don't need.

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2001 KTM 400SX #529
2000 SVCC 125cc H.S. #1
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