Re - Locating Fork Damper Rod After Fork Seal Replacement

[xbally]

Not on one of my thumpers, but on my GPZ500S.

I'm rebuilding a fork leg after replacement of a leaking seal without the special tool which stops the damper rod turning as you tighten up the allen bolt on  the underside of the fork leg through the stanchion.

I can't get  the bolt d in  how much I try.

Any tips please?

[Ian]

I have never done a Kawasaki, but I looked on the exploded view on Fowlers website. This looks remarkably like the Yamaha SRX forks. I'm sure there are detail differences! I had to make a tool to hold the damper rod, I think it's about 22mm A/F on the end of a longish piece of bar(without looking and measuring it!). Is this a similar size for yours? If so you are welcome to borrow it. (I'm in Telford). They are a bit of if faff to rebuild even with the correct tool. Failing that there's always YouTube, which seems to be the "go-to place" now.
Ian 👍

i=vS_7Q8-70Mg4vZIK

[themoudie]

Morning, just a quick word afore going for a canter! 

The SRX twin shock and Monoshock use the same method of holding the damper tube, using a large hex head on the end of a rod, with a "T" handle.

The hex sizes are different, so you cannot use the twin shock on the monoshock damper rods. I haven't looked at the Fowlers website to see if the hex head size for the GPZ500 is quoted. I am happy to post dimensions for the two tools that I have, both home made, using large HT bolts, welded onto lengths of bar, with a "T" handle.

Toodle loo, Bill

[xbally]

Thank you.

Yes mine's the same as the Youtube video.

Here are pics of what I've been trying to use todate.

The problem is the damper road part I'm trying to hold is round.

I've tried hammering the socket in the photos into the damper road with my soft faced mallet but I still can't get the allen screw started on the bottom of the damper rod through the hole in the fork leg bottom.

[xbally]

more pics

[xbally]

and again

[Ian]

Have you tried using a piece of tapered hardwood (whittled down to the appropriate size)instead of your socket. I have managed to get away using this method before now. 🙄

[xbally]

Thanks again Ian, and for the offer of the tool-I'm unsure whether it would be suitable but would be more than happy to have a ride or drive over as it's not far and a nice run.

The deep socket I tried to use was only a 10mm.

I've heard the "shoving a broom handle down the stanchion dodge" but never tried wood, although I may have a go.

When I used to work on Kawasaki triples a friend gave me 2 long bolts with a cut off nut welded together but I don't think I ever used it and it was probably lost in a house move along with a few of my other tools and bits and bobs.

[Moto63]

Come to think of it, now it’s been mentioned. The broom handle was the dodge I used years ago when I put some new Hagon springs into my xbr cafe racer. Best of luck Martin.
It seems the the word “suspension” is the curse of your life at the moment 🙄
Cheers… Michael

[xbally]

Come to think of it, now it’s been mentioned. The broom handle was the dodge I used years ago when I put some new Hagon springs into my xbr cafe racer. Best of luck Martin.
It seems the the word “suspension” is the curse of your life at the moment 🙄
Cheers… Michael

Thanks for that Michael....
Looks as though I'll be keeping you all in suspense for some time................
Hopefully NOT though.

[iansoady]

Coming to this a bit late (and I know nothing about these forks) but the inner diameter part shown in your first photo looks as if it's parting company with the outer. This may be how it's made.....

[xbally]

I think that's just how it appears in the photo Ian.

[iansoady]

Just a thought re hexagon - I'm assuming that it's an internal hexagon like an allen screw. My local steel supplier does a range of stainless and mild steel hexagons and it may be worth buying a length of that if you know the dimensions.

https://www.rapidmetals.co.uk/product/en1a-230m07-hexagon-13mm/

[Moto63]

https://www.rapidmetals.co.uk/product/en1a-230m07-hexagon-13mm/

Handy link Ian, thanks for posting. Not I need any hex bar at the moment, but who knows I may in the near future 👍
Cheers …Michael

[Propellor]

Come to think of it, now it’s been mentioned. The broom handle was the dodge I used years ago when I put some new Hagon springs into my xbr cafe racer. Best of luck Martin.
It seems the the word “suspension” is the curse of your life at the moment 🙄
Cheers… Michael

Broom handle ya say? That wooden work. Shirley.

😁😁😁