Kawasaki fork seal renewal.

[strat61]

Has anyone removed the allen bolt from the end of the fork sliders on a z650B. The Haynes manual says it takes a special tool but I ain't got one. They talk about a tapered dowel to hold it but looking down the inside of the slider it looks like some sort of hollow tube would be needed to stop the round 'bolt head' turning. Anyone know what the special tool looks like or a remedy? Please help, its driving me insane.

[Reddit]

Originally Posted by strat61

Has anyone removed the allen bolt from the end of the fork sliders on a z650B. The Haynes manual says it takes a special tool but I ain't got one. They talk about a tapered dowel to hold it but looking down the inside of the slider it looks like some sort of hollow tube would be needed to stop the round 'bolt head' turning. Anyone know what the special tool looks like or a remedy? Please help, its driving me insane.

I replaced the fork seals for a mate of mine on his Suzuki 500, and I had the same problem, but the 'tapered dowel' is exactly what I used, and it worked (amazingly - cos I made it myself!). No harm in trying?
If I remember right, I put the dowel in, turned the fork leg over and put some downward pressure on it to locate the dowel, then undid the allen bolt, and Robert is your fathers brother.

[strat61]

I've tried the dowel, had my wife & children applying downward pressure and still it don't hold. I have got the bolts out of my ol GS550, XJ550 etc but this one ere is a complete nightmare.

[Reddit]

Originally Posted by strat61

I've tried the dowel, had my wife & children applying downward pressure and still it don't hold. I have got the bolts out of my ol GS550, XJ550 etc but this one ere is a complete nightmare.

Ah. In that case, you'd better check around the local fixers, see if anyone has a tool that will help (unless anyone on here has acess to one?) Good luck.

[Reborn]

I usually use the nearest broom handle and whittle it down til it fits and give it a thump in. Another useful tip is to start the bolt turning while the leg is still in the yokes.
Oh and a pair of moles on the broom handle helps if you are on your own.

Best of luck.

Here's one I made earlier.

[strat61]

Originally Posted by Reborn

I usually use the nearest broom handle and whittle it down til it fits and give it a thump in. Another useful tip is to start the bolt turning while the leg is still in the yokes.
Oh and a pair of moles on the broom handle helps if you are on your own.

Best of luck.

Here's one I made earlier.

ok, I'll sharpen the penknife & try again this evening. At least now I've somthing to copy.

[Reborn]

Shove the broom handle in before you start whittling and tap it and you should get an imprint of the socket on the end. Taper the wood to slightly smaller than the mark. Then tap it in. Should hold it well enough to undo the bolt.

[indie]

have never had to buy special tools to rebuild forks, ive always made what i need at work, once took a 2001 gsxr1000 to a local bike shop for new seals, only to be told by the owner, 'forget it need special tools and im not buying them' took an hour at work to make said tool

[strat61]

The plot thickens. Inside the slider is a male end so the dowel does nothing. These forks must be from a different model ?? Local Kawasaki dealer is not interested, typical. Looking for a plan B.

[Reborn]

Originally Posted by strat61

The plot thickens. Inside the slider is a male end so the dowel does nothing. These forks must be from a different model ?? Local Kawasaki dealer is not interested, typical. Looking for a plan B.

Assuming the male end is hexagonal, do your hex sockets fit into the tube? Put all your extension pieces together and try a few different sockets and see if any latch on to the offending "male end".

Also have a look at this

http://www.cmsnl.com/img/partslist/f...R099564233.gif

There is a seating for the spring (no 44). Is this what is in the way?