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General Category >> Technical Documents/Reference >> How to make a fork disassembly tool
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Message started by MotoBuddha on 02/19/11 at 15:53:27

Title: How to make a fork disassembly tool
Post by MotoBuddha on 02/19/11 at 15:53:27

If you want to remove the damper rods from your forks, you'll need either a special tool from Suzuki, or you can make your own for very cheap. The tool slides down into the for tubes and engages the top of the damping rods so you can keep them from turning while you remove the bolts from the bottom of the forks.

http://i280.photobucket.com/albums/kk182/motobuddha/035558f4.jpg

You will need a bolt with a head about 24mm. I took my calipers with me to Lowe's and found a non-metric bolt just shy of 24mm.  If I remember correctly, it was a 5/8" bolt.

A couple of aisles over I found some steel tubing. The ID was the same as the OD of the bolt. In other words, the bolt slipped perfectly into the tubing.

I cut a few inches of tube to use as a T-handle. I cut a V-notch in one end of the long tube.

I went to my buddy's shop and welded the T to the V-notch end and the bolt to the other end. Presto.

If you don't have access to a welder, you can epoxy the bolt into the tube. Let it cure a few days. Then clamp vise grips onto the other end to use as a handle.  Flattening that end might help. The tool won't be doing the hard part of the work. It will just be holding the damper rods while the 7mm Allen wrench does most of the work.

-- The version of this tool Ryca sends with their fork shortening kit takes a slightly different approach. They weld a 24mm wide nut to the end of a piece of pipe. That would work too.

-- Another solution is to take a bolt like mine and hammer it into an old deep socket. You could weld it, epoxy it or just leave it if the fit is snug enough. Then snap it onto a couple of long ratchet extensions and a wrench.


Title: Re: How to make a fork disassembly tool
Post by Max_Morley on 02/19/11 at 18:36:33

Actually after I bought the special tool years ago, the other more friendly parts counter guy said, take a broom handle and taper the end to four sides about 2 " long with a1/2 or so end. Think oversized 4 sided easy out. Jam it down in the socket head with the fork inverted and zip the allen out with an air wrench. Don't know how it would work if loosening by hand. They also sell a cleaning brush with a long handle for scouring out the residue in the tube. If you live where there is a CENEX dealer you can buy good old stoddard solvent by the gallon. Makes them nice and clean for the new oil. Max

Title: Re: How to make a fork disassembly tool
Post by MotoBuddha on 02/20/11 at 11:24:45

I'm all for what works.

I suppose somewhere in the broomstick whittling process, you could jam it down against the damper rod so you get an impression on the end of the stick showing you how much you need to trim off.

Title: Re: How to make a fork disassembly tool
Post by BurnPgh on 02/20/11 at 15:56:25

if you get the broomstick trick to work, power to you, but i "ruined" 3 old broomsticks trying it. the shape id carve would just round out.

Title: Re: How to make a fork disassembly tool
Post by Boule’tard on 02/24/11 at 16:56:10

That close-enough 5/8" bolt that MotoBuddha used can also be found in the plumbing section, in the form of a brass endcap. Actual distance between flats = 1 1/8"  Does not fit the Savage forks.

http://i55.tinypic.com/s5bnd4.jpg

The brass cap threads nicely onto a piece of 3/4" iron pipe: Too big.  Somebody try the 1/2" pipe.

http://i51.tinypic.com/voa71y.jpg

..which you can of course grab with a pipewrench  :D

Just another alternative for those without access to a welder.

Title: Re: How to make a fork disassembly tool
Post by Gyrobob on 03/09/11 at 13:24:45

how long does this tool have to be?

Title: Re: How to make a fork disassembly tool
Post by MotoBuddha on 03/09/11 at 17:40:29

About 20 inches.

Title: Re: How to make a fork disassembly tool
Post by mpnoffi on 03/16/11 at 20:57:35

Just an FYI...
I have a 2001 savage.  I tried this approach as I don't have a welder.  The brass cap is exactly 1 1/8 on the flats.  It doesn't fit.  I'll go back to Lowes tomorrow to try the 24mm bolt and pipe trick.  I'll let you guys know how it works.
thanks
Noffi


48455F464F5E4B584E2A0 wrote:
That close-enough 5/8" bolt that MotoBuddha used can also be found in the plumbing section, in the form of a brass endcap. Actual distance between flats = 1 1/8"

http://i55.tinypic.com/s5bnd4.jpg

The brass cap threads nicely onto a piece of 3/4" iron pipe:

http://i51.tinypic.com/voa71y.jpg

..which you can of course grab with a pipewrench  :D

Just another alternative for those without access to a welder.


Title: Re: How to make a fork disassembly tool
Post by Boule’tard on 03/17/11 at 06:24:00

Dammit, wrong bike.  Sorry about that.  I will go back and edit my post.  Thanks for the info.

Title: Re: How to make a fork disassembly tool
Post by mpnoffi on 03/17/11 at 18:25:24

No worries Boule...
I bought a 5/8 x 4" bolt and a piece of galvanized pipe in the plumbing section (right next to the black iron pipe) in Lowes .  I ended up forcing the bolt in and it threaded all the way down so I didn't even have to tack weld it in.  Worked just fine.  

Title: Re: How to make a fork disassembly tool
Post by Boule’tard on 07/13/11 at 18:39:21

Did yall see this thing sillydilly came up with?  No welding required AND it's the right size  :D

http://img20.imageshack.us/img20/3589/forkbolt.jpg

Title: Re: How to make a fork disassembly tool
Post by sillydilly on 07/13/11 at 22:22:26

2 5/8ths 8" bolts
2 5/8ths Nuts
1 5/8s coupler

Under $7, and I assembled it on the way home!

Title: Re: How to make a fork disassembly tool
Post by Michael L on 02/22/14 at 15:42:09

Here's another option. Make sure to tighten the two nuts against eachother with as much force you got. I used the blue tool in the pic to hold it in the other end.

Title: Re: How to make a fork disassembly tool
Post by daltmyer920 on 11/04/14 at 01:22:56

ok guys, so I made the tool that sillydilly made with the 8" bolts two nuts and a coupler.
PROBLEM is when I try to remove the bottom allen nut the tool becomes loose and the two bolts no longer make one tool....
I stuck it in a vice and tightened both sides with as much force as possible.
maybe my allen nuts on bottom of fork is just super stuck? it's a 2000 and I doubt forks had been service in a looong time, seeing as when I drained there was little fluid and it was very thin.
I bought this bike about a year ago and forks started leaking about 2 months ago. would some jb weld hold it together possibly?http://suzukisavage.com/yabb2.2/Templates/Forum/new/undecided.gif
thanks for any suggestions guys.

Title: Re: How to make a fork disassembly tool
Post by verslagen1 on 11/04/14 at 07:18:18


23262B332A3E22357E7577470 wrote:
PROBLEM is when I try to remove the bottom allen nut the tool becomes loose and the two bolts no longer make one tool....


Brake the allen bolt loose 1st before taking the fork outta the tree.

The tool should just have to hold the dampers in place.
But sometimes they get heavy handed with the Loctite.

Title: Re: How to make a fork disassembly tool
Post by antjuan on 05/22/15 at 21:20:56

one thing to note, before you start disassembling your forks off of your bike, or even put your bike up on a stand to begin this process of fork seal replacement; while the bike is still on the ground with fork clamps untouched: loosen your fork caps (the bolt on top of each fork tube). Just a good idea to get them started while on the bike. because if you take them off bike and then try to loosen the caps your guna have a bad time..
And throwing them in a vice could damage them, i don't know, just a little time saver/ frustration ignorer.  

Title: Re: How to make a fork disassembly tool
Post by Gary_in_NJ on 05/23/15 at 04:32:51

antjuan,

In order to take the forks off of the Savage, the fork caps have to come off as they are integral in the triple clamp assembly. But yes, it does make sense to "crack 'em loose" by half a turn before loosing the lower pinch bolts.

Title: Re: How to make a fork disassembly tool
Post by 98savagebob on 06/19/15 at 18:32:15

Ok so is it 5/8 or 24mm there's a pretty big size difference

Title: Re: How to make a fork disassembly tool
Post by Dave on 06/20/15 at 03:31:10


4E6A606B66626F70776664626F6F030 wrote:
Ok so is it 5/8 or 24mm there's a pretty big size difference


I don't believe it is Apples to Oranges.  The 5/8" is the bolt diameter....the 24mm is the hex head size.

Title: Re: How to make a fork disassembly tool
Post by 98savagebob on 06/20/15 at 04:05:44

Ok thanks

Title: Re: How to make a fork disassembly tool
Post by RevJay on 04/27/17 at 06:58:59

Hi
I'm a newbie to SL 650 but no stranger to bikes!
I have had big trouble removing damper out of front forks, now can't tighten up.
The thought of having to locate this big nut was a bit daunting. Then I thought,  I remember using a 24mm socket for something ?  Ah ha  Towball onto towbar !
Eureka I have spares.
So for any euro zone guys there is your nut bolt easy to find!
Hope this helps  I just glued nut on bolt loctite and used my socket extensions.
Yours
Jay   Bobber on the build

Title: Re: How to make a fork disassembly tool
Post by troyrr on 06/12/17 at 15:12:45

The plumbing pipe with 5/8" brass cap did not work on my '87 Savage. I could feel it fit the shape, barely, but not enough to catch, if you know what I mean.

I saw a YouTube video of a guy replacing fork seals on a Savage. He made an offhand comment that,  if you can't get the dissambly tool to work, just reassemble the forks. The springs will provide enough pressure to loosen the bottom hex bolt.

I wanted to know if this was a viable option before making another run to Lowe's or destroying my wife's broomstick.

Title: Re: How to make a fork disassembly tool
Post by WunGun on 11/06/18 at 23:58:15

This is what I used today for my forks and it worked perfect and required absolutely no welding, gluing or whittling. This is a coupling found at the hardware store with the nuts and bolts. It was 4.89 and is metric even though it fits into my 15/16 perfect. I noticed when fitting these that the coupling sizes seem to be gauged by their internal bolt diameter so bring a socket with to be sure, though I believe it was a 20.

Title: Re: How to make a fork disassembly tool
Post by WunGun on 11/06/18 at 23:59:32

Attach it to the socket and be sure the one you have sticks out enough to catch the damper rod.

Title: Re: How to make a fork disassembly tool
Post by WunGun on 11/07/18 at 00:09:52

This picture shows the breaker bar braced by the tank. This allows you to focus on turning the bolt on the bottom without holding the breaker bar. Use something(I had a large rubber hose) to prevent damage to the bike. I had to remove the fork assembly so i could slide the coupling in horizontally so it didn't drop in down the tube. If the socket and coupling separate its OK it was effortless to fit it back in while its in the tube, in fact I took the socket and breaker bar out so I could take a break (I do everything on the street) and had no problems when I dropped the socket back in to let it grope for the coupling i left inside.

Title: Re: How to make a fork disassembly tool
Post by WunGun on 11/07/18 at 00:14:25

Brace the bottom with your free hand so that even pressure is applied and since its braced above its pretty easy. I could not get my hex sockets to fit far enough in so I bought a single 8mm hex key and used a wrench for leverage.

Title: Re: How to make a fork disassembly tool
Post by WunGun on 11/07/18 at 00:18:56

Done. Easy as pie. Eating pie... I cant bake for crap. Hope this helps.

Also I apologize for making individual posts, I am not used to forums or using sites to add pics. Learning new stuff everyday.

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