Fork Disassembly Help

[RiderX]

Greetings all!

I'm slowly starting to wrap things up on my GS restoration project, and I've run into a bit of a snag on while rebuilding the forks. The right hand fork disassembled just fine, no issues at all. However, the left hand side won't cooperate so easily. There's one in every bunch I swear...

Anyway, my problem arises when trying to remove the Damper Screw at the lower end. Part number 14 shown below. Now the Haynes manual calls for this Damper Screw (I really hope I'm using the right term there...) to be loosened prior to any other disassembly of the fork. I'm assuming the added pressure on the Damper Rod, part number 11 shown below, is what prevents the Damper Rod from spinning as you try to loosen the Damper Screw. However, that's not what's happening in my case. For me, this screw seems to just be spinning free. I'm hoping that I didn't somehow strip the end of the Damper Rod, but I kind of doubt I did...



What I'm hoping one of you fine GS owners / modifiers can provide is some form of suggestions or ideas as to what to do here...

As always, any and help is greatly appreciated!

[manofthefield]

The damper rod is just spinning in there.  This is common.  It helps to have the fork compressed, this keeps it from spinning somewhat, though it may not be the final solution. 

Here's the two options you have:
1. Use an air powered impact wrench to break the damper screw loose.  When I did it, I cut the short end of the "L" off the correct size Allen wrench and put a the impact wrench on it with the correct sized socket (impact sockets are recommended)
2. Make a tool to keep the damper rod from spinning.  Here's a post that describes the tool:  Bad Day Wrenching on the GS.  Basically you are fitting a 5/8" hex head from a long bolt into the end of the damper rod to hold it

edit: added link and description of tool

[scottpA_GS]

2. Make a tool to keep the damper rod from spinning.  Here's a post that describes the tool:  Bad Day Wrenching on the GS.  Basically you are fitting a 5/8" hex head from a long bolt into the end of the damper rod to hold it

edit: added link and description of tool

+1 Thats what I needed. However I work at a Suzuki dealer and they had the actual tool for me to use  It was a snap w/ the proper tool 

[RiderX]

Awesome. There's a Lowes just down the street, so I should be able to make that tool pretty easily. Thanks for the information!!

[Admiral Crunch]

I made the tool with two ten-inch bolts and a coupler nut held together with JB Weld.  Worked perfectly.  9" bolts would work too, but I wouldn't risk going any shorter.

[nastynate6695]

i had the same problem  10 bucks at lowes and i was good to go.  That tool should be patented and sold.  all procedes go to the website.

[NiceGuysFinishLast]

I made the tool with two ten-inch bolts and a coupler nut held together with JB Weld.  Worked perfectly.  9" bolts would work too, but I wouldn't risk going any shorter.

I did the same, worked fantastically.

[ben2go]

1= 8mm long style allen socket,2=10 inch long,5/8 bolts,1=5/8 coupler.



Fork Tool Assembled