Fork disassembly tool

[Guest]

So after searching and re-searching and grinding over about 200 posts (at least) on this and several other forums I figured out a way to make my tool to disassemble the forks completely for new fork seals and fluid flush on my 850 and her 750. After reading that the proper tool would have a 19mm hex and be at least 24" long, I found a 19mm hex socket and a 24" long, 1/2" drive extension to do the job quite nicely. The hex socket is barely larger around than the shaft of the extension so it all should go down the fork tube nicely. I know I could have simply made one but I don't have a welder (yet) and I wanted something a bit nicer than the all thread and nuts, not to mention finding the all thread and stuff locally is a pain and with stuff like that I am loathe to order it online. Stuff like that I like to hold in my hands etc. before I buy. Anyways, pics.
Pic is a bit dark but you get the idea of the overall length.

This pic shows the hex socket and its diameter vs the diameter of the extension.

Will be getting off early tomorrow so hopefully I can get the forks dropped and pulled apart with this to see how I did sourcing the bits. Total price paid was US$30 so it certainly wasn't cheap but it was cheaper than the factory tool and is a tool that will be in my tool box for a LONG time so to me it was worth it.

[Steve]

About $6.





Two feet of 1/2" all-thread and four nuts.

.

[sharpy]

about 50 cents and 30 mins......

[Steve]

about 50 cents and 30 mins......

It was only a few dollars to buy the wrenches I needed (and I have had them for several years). How much was the welder?

Not everybody happens to have a welder in the garage (shop), they are much more likely to have some wrenches (spanners).

.

[azr]

Very nice tool to add to the garage, nicely done. Don't let any local bikers know you have that tool or you will be busy

[ShadowFocus603]

Very nice tool to add to the garage, nicely done. Don't let any local bikers know you have that tool or you will be busy

Lol it's all good in my book. I'll help for whomever I can. I've only met a few other riders of any older bikes in this area.

[Grimly]

Nice work.
All I use for them is a 50mm long 12 (or 14)mm bolt with two locknuts on it, and a 19mm socket on a long extension to get it down / along there. Cost - about next to nothing.
It's true though; once you've got the tool you never need another one - that bolt kicked around my toolbox bottom drawer for years after I made it, for so long that I forgot what it was for. I was nearly making one up when I recalled that thing and the penny dropped.

[sharpy]

It was only a few dollars to buy the wrenches I needed (and I have had them for several years). How much was the welder?

Not everybody happens to have a welder in the garage (shop), they are much more likely to have some wrenches (spanners).

.

Welder was free, was where i worked. Thought it was like a show and tell this thread

[5azzmonkey]

About $6.





Two feet of 1/2" all-thread and four nuts.

.

I made one like that when I rebuilt my forks, it twisted up like a pretzel. I ended up using a long extension and a spark plug socket.

[cowboyup3371]

Other option is to use a hex head socket in a drill and loosen the bolt while the forks are still closed up

[Sandy]

I made one like that when I rebuilt my forks, it twisted up like a pretzel. I ended up using a long extension and a spark plug socket.

Wow. You managed to twist 1/2" ready rod removing a 6mm bolt??

[halz426]

I just disassembled mine. As stated earlier, I just compressed the forks and used a 3/8 impact gun on bottom bolt, then removed the caps. Super easy. No special tool.