ForkMods?

[Hogdigerdy Dog]

Is this a nut or a bolt ???

it doesn't really matter,
it's just easier to weld a nut onto the bar as you can grind the end of the bar down so it goes into the nut and makes for a easier and much better weld,

EDIT iv'e also seen it done with a length of threaded bar, using 2 nuts locked together, but it's better welded imo

[Evilchicken0]

Are you trying to turn (or hold) an allen headed bolt ??? Why not use a hex section bar
If it's a nut then maybe a box spanner into a hex bar.

This way you can use a spanner or socket on the top

[Hogdigerdy Dog]

Are you trying to turn (or hold) an allen headed bolt ??? Why not use a hex section bar
If it's a nut then maybe a box spanner into a hex bar.

This way you can use a spanner or socket on the top

not sure were reading from the same song sheet here chap

weld your nut onto a bar like this



put the bar in a vice and slide down the fork leg, making sure the nut welded onto the bar locates in the damper



then turn the alen key (hex spanner) to loosen it off (top of fork in this pic), applying downwards pressure on the fork to keep the bar located in the damper, you don't want to round it off

below right shows the damper rod the one with the small rebound spring on, at the top (in this pic) is the alen bolt, at the bottom is the end the home made tool fits in

[marti]

You are spot on h,dog
i found a length of 3/4 unf stud bar put 2 nuts on tightened them up
placed it horizontal in a large vice, got a mate to pull against the rod
while i pushed against the bottom bolt with an allen key
the 3/4 nuts measured 28mm across the flats which could of done
with being tighter but it worked!!
Only problem i noticed was both bottom bolts were missing the copper washers,
ive no idea where to get some from, thers always ptfe tape i suppose

[Taggyd]

ive got an oem one i just measured,
it's 18mm o/d
12mm i/d (so 3mm 'width' of copper)
and 1mm deep
might help you search, not sure if any brake copper fittings might do the job?

[marti]

Thanks again, but i just took a look under the forkleg and the washers are stuck inside the leg!!
However i just started to put the forks together, tightened the bottom bolt, tapped the bushes home.was just about to put the new seals in when i noticed both legs were reluctant to extend?
I have not mixed anything up, seems strange?

[marti]

Scratched my head for a sec, then realised i had been pushing down when refitting bottom bolt then
knocking the seals in and had simply bottomed out the forks, with no spring in to push back.
I simply put an old spindle in the spindle hole then stood on it and pulled the slider up!
Sorted.
Those were excellent pictures too h.dog!
On to my next job, ive got 3 inlet valves on my fzr 600r motor that are bottom spec