Fork Special Tool?

I just got back from a short ride, and to my dismay, fork oil is coming out from under the dust cover and running down the left fork. Time for new seals.

Anyway, I've studied the posts on the topic, and I'd like to fab up the "special tool" to remove inner tube. My question is does anyone know if the 19mm hex will fit on my 1981 KZ1000 CSR? The picture of the Kawasaki tool in my factory manual looks like it fits inside so I'm assuming I could make one with a hex bolt, but I just want to confirm that it's 19mm.

Also, I want to make it with a rod rather than connecting a bunch of socket extensions. How long should the rod be to reach down? It's hard to "guestimate" from the picture of the Kawa tool.

Appreciate any feedback from those of you who have worked on this model bike.

Okay, soapbox time.

Why the heck doesn't somebody make these? Like MotionPro or something? All we need is a few different end bits for the different models, and one universal t-wrench handle. How hard is that?

The existing ones from the manufacturers are made out of unobtainium.

Sure you can use a broomstick or whatever, but why? I mean for pete's sake, just about everyone who owns a bike wants one of these things, isn't the market there?

Jeez.

del

Take a broom handle, cut the end off at a 45 degree. Have abuddy hold it in the tube while you hit the bolt with an air ratchet. Free tool.

I have 1981 KZ1000J and rebuilt my forks recently. Whilst I used the old broomstick trick to hold the damper rod to get the first one out, I decided to fabricated the "factory" tool.

Take one metric bolt 22mm across the flats of the head and weld this into an old socket (or a long length of pipe) I used an old 1/2 inch AF socket into which I welded the bolt thread. Using two socket extension I was able to hold the damper assembly using the hex head, whilst undoing or retightening the Allen screw.

Not sure if 22mm would be right size for your bike but suspect the dampers would be pretty similar. Part numbers might confirm

Thanks to all who responded, and Biquetoast, amen to that - surely there would be a worthwhile market for such a tool that can be offered with optional "tips" to fit the various bikes. Hmmm.

Kiwiz, I checked the CSR to LTD part numbers, and they are the same. So I'll proceed with the 22mm. I'll start with the standard 36" rod, and cut it down to proper length plus handle. When I've completed the homemade tool, I'll try to post a pic.

Norseman, were you ever able to fab up that tool? Did it work on your CSR.

I am getting ready to do the same thing for my '82 CSR, and would like to know if the 22mm bolt is what I need.

Anybody know definitively?

Also, I think I understand how this works, but I just want to confirm. It needs to go in head side down, right? It isn't the threads that engage the inner cylinder, correct?

Thanks.

I made a simple one from a standard US 5/8" bolt and a piece of 3/4" EMT. This one fits my KZ1300. The bolt head measures almost 24 mm across.





I just welded a bolt in each end. It's a bit over long but it works.

KZCSI

Post edited by: KZCSI, at: 2008/02/23 11:32

Biquetoast wrote:

Okay, soapbox time.

Why the heck doesn't somebody make these? Like MotionPro or something? All we need is a few different end bits for the different models, and one universal t-wrench handle. How hard is that?

The existing ones from the manufacturers are made out of unobtainium.

Sure you can use a broomstick or whatever, but why? I mean for pete's sake, just about everyone who owns a bike wants one of these things, isn't the market there?

Jeez.

Hehehe...Motion Pro has made one (and it is sold by Dennis Kirk)...it is listed in their (DK) catalog as Inner Damper Rod Holding Tool and as working on KZ and Z models. Grand price of $24.99...appears to be a copy of the Kawasaki tool pictured in a number of their shop manuals. I bought one and I can only say DON'T WASTE YOUR MONEY It doesn't fit on either 1976 KZ900, 1977 KZ1000, 1978 KZ1000, or 1982 KZ1100B forks. I ended up using the old broom handle trick and an air tool. I have taken an impression of the forks from my 1100 and am considering having one made...I am stunned that Kawasaki engineers worked marvels with the older bikes but just didn't get front forks:unsure:

Mcdroid wrote:

...Motion Pro has made one (and it is sold by Dennis Kirk)...it is listed in their (DK) catalog as Inner Damper Rod Holding Tool and as working on KZ and Z models. Grand price of $24.99...appears to be a copy of the Kawasaki tool pictured in a number of their shop manuals. I bought one and I can only say DON'T WASTE YOUR MONEY It doesn't fit on either 1976 KZ900, 1977 KZ1000, 1978 KZ1000, or 1982 KZ1100B forks. ....

...I just checked it out at DK... Hey Mcdroid... wanna sell yours to me cheap? Looks like it will work on the 400 forks...

...here it is...


Post edited by: Biquetoast, at: 2008/02/23 13:51

Post edited by: Biquetoast, at: 2008/02/23 13:53

Biquetoast wrote:

...I just checked it out at DK... Hey Mcdroid... wanna sell yours to me cheap? Looks like it will work on the 400 forks...

...here it is...

PM me:)

I'll make up some of these tools (my way) for $20 plus shipping .... I can hear the cash drawer banging as I'm typing ... LMAO

Post edited by: 2M4Dale, at: 2008/02/23 16:20