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TOPIC: Front Fork Diassembly Tool/Adapter

Front Fork Diassembly Tool/Adapter 14 Feb 2020 10:47 #819300

  • Rick H.
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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.
Rick H.

1977 Kawasaki KZ-1000A1
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Front Fork Diassembly Tool/Adapter 14 Feb 2020 16:27 #819331

  • hardrockminer
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I gave the broomstick back to my wife. She's flying in a couple of days.
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 14 Feb 2020 18:23 #819336

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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.

78 KZ1000 A2A
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Front Fork Diassembly Tool/Adapter 14 Feb 2020 18:34 #819339

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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.
80 KZ750 H1 - the Kaw calf
79 KZ750 Twin - Miss Nov 2008 KZR calander
79 KZ750 Twin parts bike
78 KZ650 C2 Parts Bike
75 KZ400 Wife's old bike sold
81 KZ440 A2 LTD Wife's new bike
84 Honda 450 Rebel Wife's newest bike
Jim
Quincy,IL
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Front Fork Diassembly Tool/Adapter 14 Feb 2020 19:56 #819349

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If I ever find a fork with a condom in it I'll know who rebuilt it!
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 15 Feb 2020 08:16 #819372

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RaceTech TFDH01
1975 Z1 900
1994 KX250 Showroom Resto
2004 KX125

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Front Fork Diassembly Tool/Adapter 15 Feb 2020 09:47 #819382

  • Rick H.
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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 H.

1977 Kawasaki KZ-1000A1

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Front Fork Diassembly Tool/Adapter 15 Feb 2020 10:09 #819386

  • Mikaw
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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.
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 15 Feb 2020 10:15 #819387

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The cylinder on the KZ900 and the ‘77 1000 A have a separate threaded cap see photo
They require the “socket” female that we had made
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 01 Jun 2020 06:04 #827056

  • steve452
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I'm guessing you've made a replacement for the 57001-176 special socket. I'm currently doing a nuts and bolts rebuild of my Z1-B which I bought in April 1975 and have just discovered that the fork special tool bit I was sold 40 years ago is for the female type piston end (it's a 57001-1057). Do you have the dimensions of the cylinder end so I can get a local machine shop to run me one up. Any help would be very much appreciated.

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Front Fork Diassembly Tool/Adapter 01 Jun 2020 06:08 #827057

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After having replied to another post on this topic I've just seen yours, which answers my question! Are these available for shipping to the UK? I'm doing a nuts and bolts rebuild of my Z1-B and have hit a problem trying to get the tube out. Any help would be very much appreciated. Many thanks.

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Front Fork Diassembly Tool/Adapter 01 Jun 2020 06:17 #827058

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Out of interest, I have Kawasaki special tool 57001-1057, that was incorrectly supplied to me years ago as fitting the Z1-B. It doesn't! According to CMS in Holland it fits the following bikes;
KDX250-B1 KDX250 1981 USA CALIFORNIA CANADA
KDX250-B2 KDX250 1982 USA CALIFORNIA CANADA
KDX420-B1 KDX420 1981 UNITED KINGDOM USA CALIFORNIA EXPORT
KX250-A6 KX250 1980 USA CANADA EXPORT
KX250-A7 KX250 1981 USA CANADA EXPORT
KZ1000E1 SHAFT 1979 CANADA
KZ1000E2 SHAFT 1980 CANADA

If anyone wants the dimensions let me know and I'll post them.
Ride (and stay) safe.

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