Author Topic: Damper rod tool  (Read 132 times)

Offline Bo72

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Damper rod tool
« on: February 11, 2019, 05:57:52 PM »
Hi, I need to replace my fork seals. Last time I took it to a garage and it cost a fortune. I tried to do it myself but couldn't stop the damper rod spinning when I tried to undo the bottom Allen bolt. Found two possible tools on eBay but not sure which one I need. The seller can't tell me. Anyone know which if any are suitable? The forks are from a 2004 bike although they are fitted to a 1996 bike. Links are below.
 
https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.co.uk%2Fulk%2Fitm%2F143050064899

https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.co.uk%2Fulk%2Fitm%2F382669939453

Offline Falken Hawke

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Re: Damper rod tool
« Reply #1 on: February 11, 2019, 07:43:48 PM »
The tools you're looking at work but they are not the best tool for the job.  They are basically oversized broken screw extractors.  The inside of the damper rod is likely to get chewed up.  Done enough times and they will require replacement.

People are fabricating what would be a 24mm hex key driver (Allen Key).  See other posts concerning fork seal replacement in this forum page.

The commercial tool is a 1/2" drive 24mm hex key socket coupled to a long enough 1/2" drive extension and ratchet wrench.
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Offline Bluesmudge

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Re: Damper rod tool
« Reply #2 on: February 14, 2019, 04:33:54 PM »
If you have the newer forks (2001+ I think) then the best tool is actually one you make yourself out of a wooden broom handle. I've used the actual Suzuki tool and its not as good as wood.

The damper rod in the newer forks is smooth metal. There is nothing for a metal tool to bite into. If you clean it with acetone or parts/carb cleaner to get the oil off and then jam a piece of wood into it thats the right shape you can get pretty good purchase to turn it.

I found that mimicking the special tool shape does not work. You need to make a shaft at the end of the the broom handle that is exactly the same size as the hole in the top of the damper rod and jam the broom handle in there. The cone shape of the Suzuki special tool doesn't make enough contact to stop it from slipping.

See here:
http://gstwins.com/gsboard/index.php?topic=70830.msg851134#msg851134


« Last Edit: February 14, 2019, 04:37:09 PM by Bluesmudge »

Offline Numewsm

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Re: Damper rod tool
« Reply #3 on: February 18, 2019, 02:06:50 PM »
Hi, I need to replace my fork seals. Last time I took it to a garage and it cost a fortune. I tried to do it myself but couldn't stop the damper rod spinning when I tried to undo the bottom Allen bolt. Found two possible tools on eBay but not sure which one I need. The seller can't tell me. Anyone know which if any are suitable? The forks are from a 2004 bike although they are fitted to a 1996 bike. Links are below.
 
https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.co.uk%2Fulk%2Fitm%2F143050064899

https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.co.uk%2Fulk%2Fitm%2F382669939453

If you keep the fork complete with the top cap lightly undone so you can still remove it, and give the retaining bolt a short sharp snap turn whilst it is still under pressure, it should release without the use of the tool.
It works on my 500F no problem. :thumb:
I ride because it gives me the space to empty my mind off all that is bad and refill it with good.