Fun with fork seals, what size nut to use for factory "adapter"?

[Proxy]

Fun with fork seals, what size nut to use in place of factory "adapter"?

I've rebuilt 1 fork successfully, but in trying to take apart the other, the trick of compressing the fork and loosening the allen bolt isn't working. The damper rod still turns inside the fork.

I have heard of people putting 2 nuts on each of a threaded rod to put down in the tube to keep it from spinning. What size nut do I need for this?

 

[glad2ride]

If it is for the 1988 KDX200 forks you mentioned in another thread, then it is 30mm.

 

[Proxy]

If it is for the 1988 KDX200 forks you mentioned in another thread, then it is 30mm.

Indeed it is. However, I'm talking about keeping the damper rod from turning, not the fork.

As far as I know, there are 3 ways to solve this:
1. Use the Kawasaki pyramid-shaped adapter (don't have it).
2. Compress the fork (didn't work).
3. Make your own adapter using 2 nuts on each end of a threaded rod.

 

[paab]

The fourth way is to extend the fork enough to apply good pressure on the top out spring, then use an airgun to bang of the bottom bolt. Works great.

 

[Proxy]

If it is for the 1988 KDX200 forks you mentioned in another thread, then it is 30mm.

Disregard my previous statement, you are right about the 30mm. The trick is going to be fabricating a rod for it.

I'm thinking a metal pipe welded to the 30mm nut with a small metal bar welded across the top of the pipe to serve as a T-handle.

 

[glad2ride]

You could also buy the Jeff Fredette fork tool. He sells it at www.frpoffroad.com.

 

[Proxy]

You could also buy the Jeff Fredette fork tool. He sells it at www.frpoffroad.com.

The site says it only applies to 1995-2002 bikes.

 

[glad2ride]

Oops, the site is wrong. I have one, and it works fine.

For the sake of someone who might find this in a search, here is some information on the FRP Offroad Fork Damper Tool (Jeff Fredette). I have one of the tools, and one end is for 1995 - 2006 KDX200 (KDX 200) and 1997 - 2005 KDX220R (KDX220 KDX 220). The other end is for 1986 - 1992 KDX200. It won't work for the USD (up side down, upsdie down) KDX200 or KDX250 (KDX 250) forks. I don't know if it will work on KDX50, KDX175, 1983 - 1985 KDX200, 1980 - 1984 KDX250, KDX400, KDX420 or KDX450 forks.