Budget Fork Cylinder Holder

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31 Aug 2009 16:53 - 28 Jun 2012 08:48 #318027 by 650ed
Budget Fork Cylinder Holder was created by 650ed
KZ650C1 fork cylinders do not have a hex depression, only a round hole as in the picture. To hold this while disassembling the forks you can make a tool by super gluing a 9/16 inch OUTSIDE diameter vacuum cap to a 3/8 inch steel rod and putting other end of the rod through a big bolt to make a t-handle to give you a way to hold the rod. I put a clear tube on the rod before gluing on the cap to protect the fork top threads. The friction of the rubber vacuum cap will hold the fork cylinder, but you must apply much force while someone else uses an impact wrench to loosen the fork cylinder bolt. This tool makes tightening the bolt to the correct torque spec easy.


1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
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Last edit: 28 Jun 2012 08:48 by 650ed.

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23 Aug 2010 18:50 #393340 by Nelson
Replied by Nelson on topic Fork Cylinder Holder
I've heard of sharpening the end of a wooden broom handle and jamming it in. I haven't tried it tho.

Restoring and customizing a KZ1000. Click here to read about it.
Plated KTM, DR650, KZ1000, Former MC mechanic (eons ago). 40 yrs. of dirt and street.

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23 Aug 2010 18:56 #393342 by TheHolk
Replied by TheHolk on topic Fork Cylinder Holder
Just did the broom handle thing today - works for me...

1978 KZ650
2009 Ducati Hypermotard
1981 Vespa P200E

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24 Aug 2010 02:17 #393399 by Mcdroid
Replied by Mcdroid on topic Fork Cylinder Holder
Nice trick...thanks for the photos!

Michael
Victoria, Texas

1982 GPz750
1977 KZ1000A
1978 KZ1000A
1982 GPz1100
1975 Z2A

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25 Aug 2010 17:09 #393810 by Nelson
Replied by Nelson on topic Fork Cylinder Holder
I should mention that I've never needed a holder because I remove the damper rod bolt with an air wrench BEFORE removing the fork cap. This way the preload on the spring holds the damper rod in place. Might not always work, but it has for me.

Restoring and customizing a KZ1000. Click here to read about it.
Plated KTM, DR650, KZ1000, Former MC mechanic (eons ago). 40 yrs. of dirt and street.

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18 Aug 2013 14:56 - 18 Aug 2013 17:57 #602011 by Surt
Replied by Surt on topic Budget Fork Cylinder Holder
a sharpened broom handle worked for me too. funny enough that i unscrewed the right bolt without the broom and failed with the left one. but when i unscrewed the left bolt with the handle, the handle came out with the cyl, but it took quite awhile to remove the right cyl the same way
ps ahh well my cyls have 12 edge hex depression or whatever

ZN750 Ltd Shaft (non-USA)
Last edit: 18 Aug 2013 17:57 by Surt.

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08 Sep 2014 13:10 #646720 by z1wiz
Replied by z1wiz on topic Budget Fork Cylinder Holder
Nelson, I have used the same method with much success up until the last year. My sons 650 had them stuck, a kz1000 had one stuck and then I was working on my Z1 and had enough to make a tool for removal. The reversible end has a 17mm hex to fit the ones that have a 12 point socket end, and the other end fits the Z1 rods. The other rods with just a hole in the end I use a #6 screw extractor.

Over 30 years with z1's, Currently down to only one 75, a j model dragbike, and 2 KZ1000 dragbikes.
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