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TOPIC: Front Fork Diassembly Tool/Adapter

Front Fork Diassembly Tool/Adapter 01 Jan 2020 16:07 #816272

  • Rick H.
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I know this topic comes up a great deal, but I would like to find something that will work reasonably well at holding the front fork cylinder besides a broom stick or the like. The Kawasaki SM calls the tool I would like to see a Front Fork Cylinder Holder Part # 57001-176. I am unable to locate a source for these "sockets" save for watching Ebay. Does anyone have one and may be willing to take a few good pictures of it? Better yet would be to send it to me so I could get some measurements from it, but that's asking a lot. Apparently this adapter is as rare as the Kawasaki piston ring compressor. Thanks much....
Rick H.
Rick H.

1977 Kawasaki KZ-1000A1

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Front Fork Diassembly Tool/Adapter 01 Jan 2020 16:37 #816275

  • 650ed
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Rick H. wrote: I know this topic comes up a great deal, but I would like to find something that will work reasonably well at holding the front fork cylinder besides a broom stick or the like. The Kawasaki SM calls the tool I would like to see a Front Fork Cylinder Holder Part # 57001-176. I am unable to locate a source for these "sockets" save for watching Ebay. Does anyone have one and may be willing to take a few good pictures of it? Better yet would be to send it to me so I could get some measurements from it, but that's asking a lot. Apparently this adapter is as rare as the Kawasaki piston ring compressor. Thanks much....
Rick H.


Some KZ's had a round hole in the top of the fork cylinder and others had a hexagonal depression. Check to see which type your bike has. If it has a round hole, like my 1977 KZ650-C1, you can either make a tool as I did (see image below) or you can buy a tool for the job as shown here: www.racetech.com/page/id/70 .

[/strike]

Ed
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
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Front Fork Diassembly Tool/Adapter 01 Jan 2020 17:17 #816278

  • D3
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Hi Rick, get yourself a 7-19mm Gator Grip and weld a 500mm extension bar to it that's all l bean using on Zed 900/1000's. Ross.

[URL[/IMG][/URL]

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Front Fork Diassembly Tool/Adapter 01 Jan 2020 17:27 #816280

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Rick, I have a thread that started out looking for the same tool... I have my forks apart as the lowers are going out for polish... I can measure the head of the cylinder and get you some pics… Id be interested in a purchase of one if you have a way to machine it..

D3, unfortunately the gator grip didn't work on my '76 900 A4 forks... it would not fit inside the upper stanchion.
1976 KZ 900 A4
1976 KZ 900 B1 LTD
1978 KZ 1000 B2 LTD
Kowledge Speaks, But Wisdom Listens.
Jimi Hendrix.

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Last edit: by Mikaw.

Front Fork Diassembly Tool/Adapter 01 Jan 2020 18:16 #816284

  • z1kzonly
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Make one out of a piece of steel. Welded on anything to reach down inside. Grind down a flat side to catch the damper. I made one 40 yrs. ago with a hand drill. It still works today. I'll find it and post a pic!
Livin in "CheektaVegas, NY
Still have a Kaw! 76 KZ900 Pro-Street.
Went thru 25 of these in 40 yrs.

And The Old Girl, Harley 75 FLH Electra Glide,
Old faithful! Points ign. Bendix Orig. carb.
Starts everytime!

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Front Fork Diassembly Tool/Adapter 01 Jan 2020 20:38 #816286

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Homemade tool. You might could weld a metal wedge to the treaded end of a a 1/2" bolt, then use a socket & ratchet extensions to reach down inside the forks. My forks are different & the head of the inner cylinder looks just like a 12-pt socket, so I use a 1/2" LH-threaded bolt w nuts. I use masking tape to hold the bolt/nuts setup in place inside a 19mm socket (the 1/2" bolt I used has a 3/4" head. 3/4" = 19mm).

This won't work with most 70s models.

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Front Fork Diassembly Tool/Adapter 02 Jan 2020 09:17 #816300

  • hardrockminer
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I found this one online. I may order one.

www.bikerstoolbox.co.uk/acatalog/suspension_tools.html#a7225832
I have a couple of Z1B's restored, an '80 KZ1000LTD restored, a 1981 KZ550 restored and a 2008 KLR 650 for off road fun. My wife has a 2019 Suzuki DR 650 for on and off road.

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Front Fork Diassembly Tool/Adapter 02 Jan 2020 10:10 #816305

  • TexasKZ
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Less than £7 ( + 20% vat :blink: ) seems like a reasonable choice.
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough

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Front Fork Diassembly Tool/Adapter 02 Jan 2020 10:13 #816306

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I'm not sure there is a VAT if it's for export out of Britain.
I have a couple of Z1B's restored, an '80 KZ1000LTD restored, a 1981 KZ550 restored and a 2008 KLR 650 for off road fun. My wife has a 2019 Suzuki DR 650 for on and off road.

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Front Fork Diassembly Tool/Adapter 02 Jan 2020 14:31 #816324

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All Euro Zone Export parts are VAT free.

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Front Fork Diassembly Tool/Adapter 02 Jan 2020 14:34 #816325

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After I pulled my fork legs out of the bike I dumped all the old fluid out and looked at the top of the damper rods. Initially it looked like they were just round domes on top of the damper rods. This struck me odd as there would be no way to hold the tops of the rods if they were truly round. I then stuck a bore scope into the fork tube and took a good look at the top of the damper rod. There are two small flats 180 degrees apart on the tops. The tools/adapters with the long pointy ends are obviously not for the damper rod tops in my '77 KZ-1000. So what is needed for this is a round female socket with two flats on it to go over the damper rod top. The quest continues.
Rick H.
Rick H.

1977 Kawasaki KZ-1000A1

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Front Fork Diassembly Tool/Adapter 02 Jan 2020 14:59 #816328

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Mikaw: I don't know what the OD of a Gator Grip socket is, but the ID of my fork tubes is 1.017" or 25.43 mm. So adjusting for any tolerances you need that Gator Grip socket OD under those numbers. I thought I saw two types available. I'll have to see if I can find their OD.
Rick H.
Rick H.

1977 Kawasaki KZ-1000A1

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Front Fork Diassembly Tool/Adapter 02 Jan 2020 15:26 #816330

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So you need this kind of socket, right?



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Front Fork Diassembly Tool/Adapter 02 Jan 2020 16:06 #816332

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Scirocco thats the pot of gold at the end of the rainbow
1976 KZ 900 A4
1976 KZ 900 B1 LTD
1978 KZ 1000 B2 LTD
Kowledge Speaks, But Wisdom Listens.
Jimi Hendrix.

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Front Fork Diassembly Tool/Adapter 02 Jan 2020 16:08 #816334

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Rick, the gator grip I have is 25.80mm
1976 KZ 900 A4
1976 KZ 900 B1 LTD
1978 KZ 1000 B2 LTD
Kowledge Speaks, But Wisdom Listens.
Jimi Hendrix.
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Front Fork Diassembly Tool/Adapter 02 Jan 2020 17:23 #816341

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If your fork cylinders are similar to mine the Gator Grip tool as shown in the photo in posting #816278 above won’t work. This is because the outer circumference of the Gator Grip tool hits the outer circumference of the fork cylinder, and this prevents the pins in the Gator Grip tool from engaging the fork cylinder. So the fork cylinder will not sink into the Gator Grip tool. The images below should help show this issue. Ed



1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
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Front Fork Diassembly Tool/Adapter 02 Jan 2020 19:00 #816353

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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.
1975 Z1 900
1994 KX250 Showroom Resto
2004 KX125

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Front Fork Diassembly Tool/Adapter 02 Jan 2020 19:08 #816355

  • Nessism
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I'm not familiar with the particular forks you are working on Rick but on a lot of the Japanese forks there is a hex shape in the top of the damper rod Cylinder and Piston Unit (Kawasaki term) that needs to be held in order to remove the screw on the bottom. I use a socket like shown only I insert a long extension backwards into the socket so to speak so the hex is on the end.

BTW: I know some guys that use a broom handle sharpened into a bit of a taper on the end. Cram it down into the top of the Cylinder and Piston Unit and hold the broomstick while loosening the screw on the bottom.

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Front Fork Diassembly Tool/Adapter 02 Jan 2020 22:12 #816365

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You can modify a socket or a long pipe with slots to grab/hold the damper.



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Front Fork Diassembly Tool/Adapter 03 Jan 2020 05:32 #816368

  • Rick H.
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Scirocco wrote: So you need this kind of socket, right?




Yep Scirocco, that's the little beast that gets the job done. Thanks for putting the pictures up.
Rick H.
Rick H.

1977 Kawasaki KZ-1000A1

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