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Fork Rebuild Tool Question

Discussion in 'XJ Technical Chat' started by buzz81mach, Sep 8, 2012.

  1. buzz81mach

    buzz81mach Member

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    Just found out the the damper rod tool is discontinued. What do I do about that?

    Do I make one myself?

    What does it actually look like?

    Pics would be awesome if someone has them.

    Thanks.
     
  2. bensalf

    bensalf Well-Known Member

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    make one yourself,
    first find out what size the damper rod top socket is , my 1991 xj600 is 22mm, but i think most of the earlier bikes were 19 mm, anyhow, get a length of screwed rod of correct thread size ,and screw 2 locknuts onto the end, tighten them up, then slide it into the fork tube, to locate into the top of the damper rod,
    you will then have to hold the screwed rod at the top ,either with 2 more locknuts or some pipe grips,
    then undo the bottom allen screw in the bottom of the fork leg.
    stu.
     
  3. wwj750

    wwj750 Member

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    I read somewhere on here to use an inverted spark plug socket with some long extentions. Most spark plug sockets have an allen-shaped top that might fit your damper rod.
     
  4. permissiontolandfmx

    permissiontolandfmx Member

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    If you use an impact drill after starting the bottom allan bolt it will grab and you won't require any tool.
     
  5. mook1al

    mook1al Member

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    Yep, works great, just need a lot of extensions.
     
  6. bigfitz52

    bigfitz52 Well-Known Member Premium Member

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    Just be sure the spark plug socket has the correct-sized hex on it. Then it works great.

    As above, most of the '80~'83s need a 19mm.
     
  7. Ground-Hugger

    Ground-Hugger Member

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    I welded a proper size nut onto a piece of threaded rod of popper length then welded anther nut to the other end. Now I have a custom tool in my box for doing the job.
    Not all spark plug sockets have the square hole assessable from the inside. Mine have a round hole for the plug to fit through so I had to fab a tool for the job.
     
  8. schmuckaholic

    schmuckaholic Well-Known Member

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    Am I the only one that did the thing with the electrical conduit and a 1/2" bolt?
     
  9. mook1al

    mook1al Member

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    Hadn't heard of that one. However, I used the spark plug socket and it worked great. And, I do not have a specialized tool in my tool box. When I am done, just take the socket and extensions apart and use them for whatever need I have.
     
  10. warthogcrewchief

    warthogcrewchief New Member

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    It should be the same as the Ventures. I got two -2 foot sections of steel pipe with threading at both ends. While at the hardware store, I had them cut one of them in half. I bought a threaded "T". I got the bolt (I believe to be 22mm head) and used JB weld to hold it in place. THE JB WELD DOES NOT HOLD! You need to weld the sucker in place. She works like a charm in keeping the piston from turning.

    Another option that works (that most m/c repair shops do) is to get an air (or electric) impact gun on the bottom bolt. When I do this, I get the socket set that have the allen key tip attached. Sometimes this works.

    Here's a picture: [​IMG]
     
  11. Buffalony

    Buffalony Member

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    Do you have access to a welder/some one who welds? Its just a T-bar with a nut on the end. I had a buddy weld one up for me for less than a 6-pack. make sure u use blue thread lock on 3-5 threads of the damper bolt upon reassembly. Pulled mine off an the last person used plumbers tape!!

    Theres also a way to make the tool with some threaded rod, and a bunch of nuts. Was cheaper for me to buy a piece of rodr and a nut.

    Good luck


    BTW.. JB Weld Sucks. Wart knows
     
  12. adrian1

    adrian1 Active Member

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    "Am I the only one that did the thing with the electrical conduit and a 1/2" bolt?"

    Probably! :) How do you secure the bolt to the conduit BTW
     
  13. razz1969

    razz1969 Active Member

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    I second the impact wrench method, works perfect every time.
     
  14. TIMEtoRIDE

    TIMEtoRIDE Active Member

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    Does the SECA 900 need a different size than 19 MM ??
     
  15. adrian1

    adrian1 Active Member

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  16. schmuckaholic

    schmuckaholic Well-Known Member

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    Cotter pin. Those of you with the XJCD, from the main menu, look under "chassis" and you'll see "Mark Yerkes' Fork Holding Tool".
     

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