Can't remove damper rod

[Guest]

I would rather not purchase a special tool to dismantle my forks. Trying the dowl method. I did so in '92 but now it is not working. Does anyone understand the mechanism enough to tell me how to break the nut loose? The dowel is secured but spins after enough torque on the nut. Need to have my bike on the road ASAP. Please help...

[Steve]

I can understand not wanting to spend a lot of money for a special tool, but are you also against spending about $6 to make one?

Get a piece of 1/2" all-thread rod that is two feet long, and four nuts. Put two nuts at one end, jam them together,
do the same thing at the other end, but leave about 3/4" of rod sticking out. (You can make both ends the same, to make it easier.)




Put your new tool down the fork leg, you will feel the nut fit into the top of the damper rod and hold it in place.
Put a wrench on the inner nut at the top to hold the tool, remove the screw on the bottom of the fork.

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[posplayr]

If you use an impact wrench then it doesn't take much force at all on the inside nut to spin out the bolt.

I have a long piece of copper pipe that fits nicely down the center of my 88 GSXR forks and provides just enough friction.

[chef1366]

I keep the spring in and use an impact.

[Dogma]

I keep the spring in and use an impact.

Same here.

Take the screw out of the bottom before taking the rest of it apart (but after draining it). Invert the fork leg and grip it with your feet. With your left hand, hold it against your right thigh. Make sure of the direction the rattle gun will turn. Make sure the bit is well seated in the screw's socket. Put your weight on the fork leg to compress it and pull the trigger.

Reassembly is the same, but turning the other way and with some blue loc-tite applied. Granted, with this method you're sort of spit-balling the torque.

[bluehwy]

You guys rock! I did see the earlier post of the all thread tool and for some reason it didn't click. But I get it now, the exposed nuts are to get a wrench on. I also thought of an impact right before I posted but couldn't find the right size. I'm on the right track. Thank you for your help.

[bluehwy]

By the way, Steve. That is the weirdest looking tape measure I have ever seen. 8-)

[chef1366]

By the way, Steve. That is the weirdest looking tape measure I have ever seen. 8-)

It probably dates him.

[chuck hahn]

19MM bolt welded into some conduit. Make the long leg at least 22 inches.Once the bolt head locks in to the dampner rod, simply flip it over and stand on the handles and you can use both hands to remove the allen head bolt. May help to heat the bolt a bit in case it has been loctited in. Be sure to REPLACE the crush washers that seal the fork and bolt.

[Homie]

By the way, Steve. That is the weirdest looking tape measure I have ever seen. 8-)

Is that one of those folding rulers? A 6' ruler that folds up in 6" segments and kind of looks like a brick when its all folded up? Yeah, my grandpa had one of those.....

[Quick Cal]

Your bike is different than a 650, but a broom handle works on the 650. Might be worth a try for free before you go spend money.

[Steve]

By the way, Steve. That is the weirdest looking tape measure I have ever seen. 8-)

Maybe because it's not tape?

It probably dates him.

No, it was never that kind of relationship.

Is that one of those folding rulers? A 6' ruler that folds up in 6" segments and kind of looks like a brick when its all folded up? Yeah, my grandpa had one of those.....

Yep, that's it.

I used that ruler when I was working in construction over 40 years ago.

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[JATO]

I welded a 19mm bolt head to a length of 1/2 inch round stock and then welded an old socket the other end so I can put a ratchet on it to make life easier. Over thought but I like to weld.

[Steve]

I welded a 19mm bolt head to a length of 1/2 inch round stock and then welded an old socket the other end so I can put a ratchet on it to make life easier. Over thought but I like to weld.

Works GREAT, if you have a welder.

Another option that has been suggested in the past is to take a spark plug socket that has a hex on the end, turn it backwards and put it on a VERY LONG extension, then stick it down the fork tube. The concept is pretty much the same as your creation, but without the welding.

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