First foray into fork rebuilding

[ddaniels]

Can somebody explain to me how you use the special homemade tool? What is it for? Thanks.

[recoush]

The tool is a threaded rod with 2 nuts and lock washer,used to remove the fork retainer nut that is holding the springs in place.
I forget what the size is for the rod but the rod size determines the Nut size of the threaded rod on both ends the rod needs to be thread the nuts flush and tighten the two nuts against the lock washer (both ends the rod is about 36" long r longer

insert the threaded rod into the fork tube and just like a wrench it fits into the fork retainer

as you need to apply a fair amount of toque to remove the Fork Spring retainer.
You have to use a downward force and beware there is still tension on the springs let off slowly or you will be in for a surprise

[dorkburger]

In my case I locked a pair of vice grips on the top, then turned the allen bolt in the bottom of the forks until the vice grips stopped on something solid (my bike isn't that nice, so no worries) then the bolt broke loose.

[ddaniels]

Nope, still don't get it. Anybody have pictures?

[ddaniels]

Ok, nevermind. I just found another thread where Steve posted a picture of his "tool". I also like the idea of a sparkplug socket and extensions. I have those, and a very long extension, about 18", plus three or four other 4" extensions. I'll try that.

Incidentally, I tried breaking those bolts loose with an impact wrench while the forks where still clamped in the triple tree. I used the fork brace to keep the bottom fork housings from turning. No go. Is there some reason why that would not work?

[ddaniels]

Spark plug socket won't work. Doesn't fit down in there.

[Johnny]

What did you use (if any?) to seal that allen bolt on reassembly?

[dorkburger]

It has a copper washer.

[Johnny]

It has a copper washer.

So, no expensive chemicals then. The manuals for my 250 list "Suzuki Thread Lock Cement" and "Suzuki Bond Number 4". I guess any thread lock will do, but that Bond no 4...

[Johnny]

Nope, still don't get it. Anybody have pictures?

The actual tool (or the bit for it) may vary from different bikes (I guess), but they are definitely still in production, I just checked. For instance, the one for my GSX250 would be this: http://www.partzilla.com/parts/detai...940-34520.html, along with the "socket" needed for it: http://www.partzilla.com/parts/detai...940-34561.html. Can't find "Bond no 4" though, but it's part number used to be 99000-31030.

[ddaniels]

Well, I asked my GSX1100G email group and the answer was unexpected. 1" square steel tube, about 3 ft. long. Sure enough, it fit right into the 12 point hole in the top of the damper rod. cheap and easy. I just clamped the tube into my vise while holding the fork against it and was able to break that bolt loose.