Well it depends on your fork tube. For a 96 RM250, I used 1.5" diameter cut in two and had to grind the cut edges down to make a tight fit over the fork tube. Just becareful. I didn't tape the two pieces together and when I went to drive the seal down, the split edges came apart and really pinched the palm of my hands bad.
My advice is to buy the tool. You may not like putting out the money but everytime you do your fork seals you'll have it. You can get them from Kawasaki or Race-Tech. I think the Kawasaki driver is cheaper.
It worked for me. I took a piece of 1 1/2 schedule 40 and slit it from top to bottom so it could be opened up a bit to fit over the tube and it seemed to work great. I agree to make sure not to pinch your hand (I did it too). :scream:
Man TIMR .. It is a pain having to work at work .. Ya know what I mean? ... It has slowed some now so I will be around a bit more ... :D
TnKDX'er I am not real sure what that is the Jeff sent to you but I would ck with him on it. It sounds like he intended for you to use this as a preload spacer? .. Like I said you might want to ck with him.