Special tool for fork disassembly
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Hello guys, I need to replace the fork seals on my DT 125 R and it requires a special tool to disassemble the bottom bolt on the fork, in this video I found, it looks like a square, any additional information on that? thanks
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Hello guys, I need to replace the fork seals on my DT 125 R and it requires a special tool to disassemble the bottom bolt on the fork, in this video I found, it looks like a square, any additional information on that? thanks
It’s a hexagon that happens to be the same size as the swing arm bolt, 22mm I think. Someone on this site made a tool from one IORC
You could make a tool by welding a 22mm nut on either end of a threaded bar...Or you could do what I did
Get a good, strong, hardwood broom handle and whittle a ‘squared off’ point onto the end. It doesn’t have to be a sharp pointed end. Just has to fit inside. Give it a whack with a lump hammer to set it and hold with a set of gorilla/vice grips. Or Stillsons, whatever, while you undo the fork bottom Allen bolts...
Just make sure the bottom Allen bolts are lubricated, free and turning first... -
oh, thank you, I will do a bit more research and maybe make me the tool
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oh, thank you, I will do a bit more research and maybe make me the tool
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It’s a hexagon that happens to be the same size as the swing arm bolt, 22mm I think. Someone on this site made a tool from one IORC
You could make a tool by welding a 22mm nut on either end of a threaded bar...Or you could do what I did
Get a good, strong, hardwood broom handle and whittle a ‘squared off’ point onto the end. It doesn’t have to be a sharp pointed end. Just has to fit inside. Give it a whack with a lump hammer to set it and hold with a set of gorilla/vice grips. Or Stillsons, whatever, while you undo the fork bottom Allen bolts...
Just make sure the bottom Allen bolts are lubricated, free and turning first...The damper rod is 27mm where the special tool fits (same size as the rear wheel spindle hex). You can make one by cutting the threaded end off a rear wheel spindle (try and find one with a knackered thread) and grinding an 18mm hex onto the shank so it fits into a socket. Then just loads of 1/2" drive extension bars.
As you've got the grinder out, make the 18mm hex long enough to fit into a deep socket to get maximum purchase.
Torque setting for the bottom bolt on reassembly is 62Nm with blue Loctite and a new copper washer and this tool was strong enough!
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The damper rod is 27mm where the special tool fits (same size as the rear wheel spindle hex). You can make one by cutting the threaded end off a rear wheel spindle (try and find one with a knackered thread) and grinding an 18mm hex onto the shank so it fits into a socket. Then just loads of 1/2" drive extension bars.
As you've got the grinder out, make the 18mm hex long enough to fit into a deep socket to get maximum purchase.
Torque setting for the bottom bolt on reassembly is 62Nm with blue Loctite and a new copper washer and this tool was strong enough!
@HOTSHOT-III that’s a great idea, I will try to make myself a tool like yours! Thanks for the tip
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The brush/rake handle idea was in the Haynes manual I think. It does work as long as the handle doesn’t shiver into splinters!...
Search the site for ‘fork tool’ maybe?...
@SpookDog i think the idea of making the tool is great, since I work at a car shop I will be able to make the tool easily, thanks for the tip, the Haynes manual has a ton of good information!
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@SpookDog i think the idea of making the tool is great, since I work at a car shop I will be able to make the tool easily, thanks for the tip, the Haynes manual has a ton of good information!
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Lucky bugger having a workshop!..
27mm nut welded to a long steel bar with a ‘T’ bar at the end. You could sell them!...
@SpookDog I made myself a little tool I will send a picture when I use it, it’s simple and uses the same logic
