Hi all,  can I ask if anyone knows what type of head is on top of the damper rod on the Paoli fork on an F K5 model please?    I have the fork out with its top off and the lower damper bolt is just turning the inner bits.

Looked at flyingbeagle71 's post made in 2006 and saw no answer was posted.   Can't make out the picky of the special tool either sadly.  Would be grateful for any info from others who have grappled with this prob.

Cheers everyone.

Stu   

put the spring and spacer back in, and reinstall the fork cap.  the tension from the spring should keep the internals from turning

Thanks there but I tried that already, seems that no matter how much force I apply to the top of the damper ( including the broomhandle trick) it wont break the grip it has on the rod.

Stu

Just to let you all know I found a site which gives me what the Suzi special tool looks like, so i know what the head looks like now too.   Thanks anyway and heres the site for anyone who needs to find a special tool that Suzuki use.
http://www.alpha-sports.com/tools/suzuki_tools.htm

Stuart

Sir, you  can make that tool for about 10 bucks at Lowe's or HD. Here is what it looks like....


and you'll need the piece of pvc to put the seals back in place if I remember right. I did this like maybe 4 years ago.

Hi Average,  nice photo and thanks but are you certain that it is the same model/type forks you used that tool on?  The 09940-34531 tool picture recommended by the manual is shaped like a countersink head with grooves on.   Also I can see nothing to grab onto at the bottom of tube.  Looks to me that the tool is only used to stop the bottom tube rotating by acting like a plug and gripping the sides.

Oh well, maybe try exerting pressure by another method.

Stu

if i remember right there's an Allen head key at the bottom of the fork tube were the axle goes through. I think it's a 6mm....

Just shine a light down the fork tube and take a look for yourself. IIRC, the head on a 5/8ths bolt is perfect for holding the damper rod while you remove the allen screw in the bottom of the fork leg.

Average: You are correct that there is a allen head bolt at the bottom of the fork leg. However, once the bolt is loose, the damper rod will simply spin in the fork body. The rod needs to be held in place from the top of the fork tube.

Jeremy, my experience was that spring tension is not sufficient to hold the damper rod, especially when the factory applies lock-tite on retaining bolt.

b1, you are correct. there's a how to on here. before i got the Kat fe i used it to do my seals and install my P springs. that tool, a 5/8 or 16 mm socket, a ratchet and allen set....oh and the pvc pipe and you're golden...

Hi all, got the things apart in the end and now all is clear to me.  I tell you it was a PIG!  I may have been unlucky but the guy who first made these must have used half a tube of loctite on them.   

The tools that were shown would have no more mechanical function at getting the tube out than a broomhandle would, ie just to put pressure on the top of it.  As you see the damper rod top is just a smooth flat cone shape and everything you press on it just slides.  the only way I got to exert enough pressure was to reinsert the spring washer against it and then use a large bearing puller to screw gingerly down on it.  even then it took more force to press and hold than I could ever achieve with a simple hand tool. 

Here are the pic links

http://www.flickr.com/photos/52043878@N04/4791037377

http://www.flickr.com/photos/52043878@N04/4791670642/in/photostream

Cheers again,  Stu

The way i just got mine out is not just by pushing the broom handle against it, but cutting a long taper into the end, then bashing the soft wooden handle into the damper rod. (the hole is 15mm). Wedging it in there helped to keep the sucker in place.

I wish i had found this thread in my original search instead of making the bolt tool discussed for early model bikes.

Then, you made it harder than it was,sir. If you used the tools that were mentioned than you shouldn't have had a problem. I'm looking at the 'fische and don't see much of a difference between the 90 and 05 fork internals