Fork Tools

[kelseybrent]

I've got a set of gold valves coming from FRP for my 2003 KDX200, so I had to remove the valve assemblies from the bottom of the forks. I did a search to see what tools I would need. I liked the cylinder holder method better than the impact wrench, so I needed a cylinder holder and a 14mm hex wrench. The JustKDX site has a diagram for the cylinder holder. I had some scrap 1" OD pipe here at work, so I just needed a 27mm nut to weld on the end and a 14mm hex socket. McMaster-Carr (330-995-5500) delivers next day to work, so I use them. I ended up getting a 5/8-11 (27mm=1.063") flange nut, because I could buy just one of them and the flange OD helps line up the tool. The diagram calls for an ID of 5/8 or greater, so I opened up the nut to 5/8, but it may have still worked with the threads.

Here's the parts list:
91030A035 5/8-11 flanged nut $2.20
5571A71 14mm hex socket, 1/2" drive $10.10
5522A33 3/8-1/2" drive adapter $3.91 (for my torque wrench)

Sorry, that was longer than I thought. Everything worked fine and the forks are apart. Couldn't believe how much oil was still in there even after draining and pumping.

 

[Braahp]

Its really an easy process huh? If you just compress fork while using impact on big hex it would have held and came right out.

 

[kelseybrent]

Easier than getting my cheap ass to buy an air compressor and tools ;)

 

[wibby]

If you just compress fork while using impact on big hex it would have held and came right outIts really an easy process huh?

Not!

I tried on mine and eventually gave up and took them into a shop, I went back the next day and the guy says "I can't get 'em apart"

So then I tried making the cartridge holder tool, but nobody around here carries large metric nuts, I found a large standard nut that fit pretty good but it was to soft and it just rounded off when I applied some torque on it.

So.... I bought the darn tool from FRP!! :eek:
Shoulda done that from the beginning!

 

[gwhII]

Hey, thanks for the pointer to McMaster Carr. I forgot about them. I looked in the Grainger catalog and didn't find any large hex sockets. I just used a 9/16" Grade 8 bolt. Not next time...

The cartridge tool I made held up through the disassembly and reassembly process but like you said, the metal's soft. Since it won't be too regular a job, I think it'll hold up for awhile. I bought spare nuts so that I could always weld up another.

Best,
Greg

 

[JasonWho]

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[gwhII]

Thanks, Jason. I normally don't check the local autoparts store. I will next time. :-)

Best,
Greg

 

[JasonWho]

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[mxfrank2001]

I have you all beat in the "cheap ass" dept. I made a damper rod holder out of a short piece of scd40 1" PVC pipe with a tee at the end. I just had to mill of about 1 to 2 mil. off the diam of the pipe to get it to fit into the damper rod. I then cut four 1/4 in. slots in the end in a cross pattern to fit into the damper rod slots. Total cost? $1.00 not bad and works great!

 

[mbolton]

THANKS JasonWho!! I spent my day dealing with this. After very unsuccessfully searching for a 14mm hex, I never thought to check Auto Zone. Came home and figured I check DRN, knew their had to be a solution! Anyway, the Auto Zone down the road has two sets, still $7.99. Will have it in my tool set tomorrow. Thanks again, I love this site. :)

Mark

 

[JasonWho]

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