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How to make a fork disassembly tool (Read 1520 times)
MotoBuddha
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How to make a fork disassembly tool
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.



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.

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« Last Edit: 12/08/12 at 12:50:32 by Oldfeller »  

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Max_Morley
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Re: How to make a fork disassembly tool
Reply #1 - 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
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MotoBuddha
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Re: How to make a fork disassembly tool
Reply #2 - 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.
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Re: How to make a fork disassembly tool
Reply #3 - 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.
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Boule’tard
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Re: How to make a fork disassembly tool
Reply #4 - 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.



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



..which you can of course grab with a pipewrench  Cheesy

Just another alternative for those without access to a welder.
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« Last Edit: 03/17/11 at 06:28:44 by Boule’tard »  

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Gyrobob
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Re: How to make a fork disassembly tool
Reply #5 - 03/09/11 at 13:24:45
 
how long does this tool have to be?
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MotoBuddha
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Re: How to make a fork disassembly tool
Reply #6 - 03/09/11 at 17:40:29
 
About 20 inches.
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mpnoffi
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Re: How to make a fork disassembly tool
Reply #7 - 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

Boule’tard wrote 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"

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  Cheesy

Just another alternative for those without access to a welder.

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Boule’tard
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Re: How to make a fork disassembly tool
Reply #8 - 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.
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mpnoffi
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Re: How to make a fork disassembly tool
Reply #9 - 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.
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Boule’tard
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Re: How to make a fork disassembly tool
Reply #10 - 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  Cheesy

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sillydilly
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Re: How to make a fork disassembly tool
Reply #11 - 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!
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Michael L
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Re: How to make a fork disassembly tool
Reply #12 - 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.
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« Last Edit: 03/14/14 at 05:43:31 by Michael L »  

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Re: How to make a fork disassembly tool
Reply #13 - 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.
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verslagen1
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Re: How to make a fork disassembly tool
Reply #14 - 11/04/14 at 07:18:18
 
daltmyer920 wrote on 11/04/14 at 01:22:56:
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.
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« Last Edit: 11/20/14 at 11:29:59 by verslagen1 »  

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