TOPIC: Front Fork Diassembly Tool/Adapter

Kidkawie wrote: Spring compression/pressure on the damper is all thats needed. I service/tune modern MX suspension, that "special tool" is not needed, otherwise you would see a bunch of them for sale.

I understand what you are saying Kidkawie. After reading a bunch of old posts on this subject it's pretty clear that many have accomplished holding the damper rod in several ways. Most times by simple friction holding the rod with a broom stick or wedging a broom stick between the rod end and fork cylinder. While these may all work to one extent or another I was looking for a different solution that will handle even the most stubborn of removal situations and the obvious answer is a socket to receive the damper rod end, or an adapter of some sort to do the same thing. With all the advancements in machining and tool design I would think making this adapter would be doable, but at what cost? So now that I know what the adapter looks like I can show pictures to some of my friends that are tool makers/machinists and see what they have to say.

90% of the time there is always a "work around" when the situation calls for a special tool, like removing plastic push pins on car bodies today, but the special pliers made for that function sure make it easier and save time. I still remember trying to get old GM door and window handles off when they used U-shaped clips to hold them on. I was too broke or cheap at the time to buy the special tool for the job and would fiddle around with a couple of small screwdrivers trying to push the clips off. When I bought the special tool for the job I thought I died and went to heaven it was so easy! Slip the tool behind the handle, line up the clip slot and push clip out. Almost took longer to type that out then do the job.
Rick H.

this is probably as good on how to dismantle forks/replace seals as anything IMHO

Rick H...
If price is acceptable I’d be interested in a socket...

Mikaw wrote: Rick H...
If price is acceptable I’d be interested in a socket...

Now that I know the details of this socket/adapter I will track down one of my machinist buds and see if they can't make something up for me. I will let you know what I find out.
Rick H.

To bring closure to this thread, I had a friend make up a couple of sockets similar to the Kawasaki factory damper socket. They aren't exactly the same but they work quite well for holding the damper rod. Mikaw was kind enough to borrow his damper rod to me for fitting purposes. The two initial sockets were made using a computerized EDM process which as it turned out took quite some time. All total it was a 5 hour process for two sockets from start to finish. If my friend were to do this again he told me he would use a different more mechanical process on a mill.

In any event, if anyone should desire to have one of these sockets please let me know. The one I have works just as it should and I believe the one Mikaw has works just as good. My "guess" as to cost at this time would be around $75.00 for the socket plus shipping. At todays shop labor rates that is a bargain, but shipping and insurance would be extra. From what I can find out this socket, part # 57001-176, fit many Kawasaki models but is no longer available. I have no idea what the last retail was on it because quite simply, no one has one for sale. I have a couple of pics of the final prototype. Later ones will no doubt look a bit different. One end fits the damper rod cap and the other fits a 3/8" extension but is a "push" fit.

If you are interested in one of these please let me know via PM and I will compile a list and keep everyone updated on the process. And yes you can keep using a broomstick if you like.....

Rick H.

I gave the broomstick back to my wife. She's flying in a couple of days.

I've done a few fork seal jobs and never needed to make a broom stick style tool but I finally had trouble with one spinning on my wife's Yamaha and needed one
So here is my version using latex glove fingers to help grab metal and it worked well.

hardrockminer wrote: I gave the broomstick back to my wife. She's flying in a couple of days.

Ouch, that's hard rockminer, and on Valentines Day no less, but funny none the less.

If I ever find a fork with a condom in it I'll know who rebuilt it!

RaceTech TFDH01

Well I can only assume there must be some confusion over what the Kawasaki tool #57001-176 actually did. In simple terms it was an oddball socket that Kawasaki designed with a female opening in it to accept a similarly oddball shaped fork damper cap. I still don't know how using a broomstick one is able to grab hold of a damper cap that has no indentation in it to accept anything what-so-ever other than a large Kawasaki designed odd shaped socket. I can only assume those that use the broomstick are lucky enough that sheer friction between the damper cap and broomstick is enough to break the bond of the bottom retaining bolt and the damper rod. The Race Tech rod will not work in this application.
Rick H.

Rick, they have different damper/cylinder then our forks. My ‘78 has the type the are using the “broomstick” trick on. The top of the cylinder is a female design. Some are smooth and some like the 650 forks have a hex machined into them. Either way it’s a female that needs a male tool. Our cylinder has a male boss. No way a male to male connection will work. See photo of factory tool that Kaw supplied for the cylinder with female top.