Wilsons Sandbox

Posted: **Thu Oct 30, 2003 4:49 pm**

I'm trying to disassemble my front forks in order to replace the fork seals. I can't seem to remove the Allen bolt from the bottom of the slider, without some sort of special tool. Does any one know if this is something that can be easily fabricated? Is there some way around this special tool? It seems to be needed to keep the tube inside the slider from spinning while you loosen the Allen bolt, but there doesn't seem like anything for the tool to grab on to down inside the slider. It almost looks like the special tool is square, and just wedges itself inside the round tube? Scott..

Posted: **Thu Oct 30, 2003 5:01 pm**

At 10:49 PM +0000 10/30/03, ScottZinski wrote:

>I'm trying to disassemble my front forks in order to replace the fork >seals.

You don't need to disassemble the forks to do the seals. Just remove the clips above the seals and blow them out with air pressure. Mark -- http://www.personal.psu.edu/mjv2

Posted: **Thu Oct 30, 2003 6:24 pm**

http://www.devonjarvisphoto.com/posted/emulators/damper_rod_holder_construction.html This was for the DRZ forks I'm using but the instructions will work for making a KLR650 damper rod holder. Sometimes an air impact wrench will work. As Mark mentioned, you don't actually need to disassemble the forks to change the seals. It makes it a lot easier to thoroughly clean everything though. Devon scottzinski@... wrote:

>I'm trying to disassemble my front forks in order to replace the fork >seals. I can't seem to remove the Allen bolt from the bottom of the >slider, without some sort of special tool. Does any one know if this >is something that can be easily fabricated? Is there some way around >this special tool? It seems to be needed to keep the tube inside the >slider from spinning while you loosen the Allen bolt, but there >doesn't seem like anything for the tool to grab on to down inside the >slider. It almost looks like the special tool is square, and just >wedges itself inside the round tube? > >Scott.. > > >

Posted: **Thu Oct 30, 2003 10:11 pm**

If you don't have an air gun, (which works great), try using a broom handle inside the fork leg to hold that piece from spinning. Fred http://www.arrowheadmotorsports.com http://www.angelfire.com/ut/moab/cmc.html

----- Original Message ----- From: "ScottZinski" To: DSN_klr650@yahoogroups.com> Sent: Thursday, October 30, 2003 3:49 PM Subject: [DSN_klr650] Kawi special tools, and such.. > I'm trying to disassemble my front forks in order to replace the fork > seals. I can't seem to remove the Allen bolt from the bottom of the > slider, without some sort of special tool. Does any one know if this > is something that can be easily fabricated? Is there some way around > this special tool? It seems to be needed to keep the tube inside the > slider from spinning while you loosen the Allen bolt, but there > doesn't seem like anything for the tool to grab on to down inside the > slider. It almost looks like the special tool is square, and just > wedges itself inside the round tube? > > Scott.. >

Posted: **Thu Oct 30, 2003 10:16 pm**

In a message dated 2003-10-30 2:53:10 PM Pacific Standard Time, scottzinski@... writes:

> > I'm trying to disassemble my front forks in order to replace the fork > seals. I can't seem to remove the Allen bolt from the bottom of the > slider, without some sort of special tool. Does any one know if this > is something that can be easily fabricated? Is there some way around > this special tool? It seems to be needed to keep the tube inside the > slider from spinning while you loosen the Allen bolt, but there > doesn't seem like anything for the tool to grab on to down inside the > slider. It almost looks like the special tool is square, and just > wedges itself inside the round tube? > > Scott.. > >

Put the lower fork leg in a soft jaw vice and have a friend pull against the upper leg and this usually get enough friction for the allen bolt to break free. If it don't a special tool is easy to buils. I went out ot the garage looking for mine to get the sizes - you got to your ACE hardware get a length of threaded rod and two nuts, one serves as the jam nut. Without finding mine I can't call out the nut and thread size but I know someone out there knows the size. Pat G'ville, Nv [Non-text portions of this message have been removed]

Posted: **Thu Oct 30, 2003 11:40 pm**

Thanks for all the removal methods.. I'll be trying them out tomorrow.. Blowing the seals out seems the easiest, but I also want to clean and inspect the damper assembly as well.. I appreciate everyones reply. Scott..

Posted: **Fri Oct 31, 2003 8:02 am**

I made my own fork disassembly tool by tack welding a 5/8" nut (13/16" wrench size I think) to the end of an old sparkplug wrench. I just use some long socket extensions to reach inside the fork tube to hold it. Paul Streeter Shoreview, Minnesota I'm trying to disassemble my front forks in order to replace the fork seals. I can't seem to remove the Allen bolt from the bottom of the slider, without some sort of special tool. Does any one know if this is something that can be easily fabricated? Is there some way around this special tool? It seems to be needed to keep the tube inside the slider from spinning while you loosen the Allen bolt, but there doesn't seem like anything for the tool to grab on to down inside the slider. It almost looks like the special tool is square, and just wedges itself inside the round tube? Scott

Posted: **Fri Oct 31, 2003 1:53 pm**

On Fri, 31 Oct 2003, paul wrote:

>they took a wrong turn in a bad neighbourhood and ran out of gas. as they >didnt have a cell phone and didnt wish to leave the vehicle

No cell phone.

Posted: **Fri Oct 31, 2003 1:55 pm**

On Fri, 31 Oct 2003, ScottZinski wrote:

>Thanks for all the removal methods.. I'll be trying them out tomorrow.. >Blowing the seals out seems the easiest, but I also want to clean and >inspect the damper assembly as well..

I hit one of mine with 130psi over and over again and couldn't blow it out. Had to disassemble the forks anyway, so no big deal. RM

Wilsons Sandbox

update to missing persons nklr

kawi special tools, and such..

kawi special tools, and such..

kawi special tools, and such..

kawi special tools, and such..

kawi special tools, and such..

kawi special tools, and such..

kawi special tools, and such..

update to missing persons nklr

kawi special tools, and such..