465H fork tool dimensions needed

[tony27]

Having serious problems getting my 465 forks apart, can't get the damper rod bolt out.

So far I've tried the rattle gun & pulling the forks down to the point that the rear wheel is off the ground but still no joy

Can anyone give me the rough dimensions to make the tool up for holding the damper rod, I suspect from looking at a old post from Ji Gantor that the nut size would be about 16mm. Can someone confirm this

[holeshot buddy]

is it spinning or locked up

[Zakk]

i've found the best way is to use a wooden broom handle, sharpen the end a little so it fits into the dampner tube and hammer it in. you'll have to hold onto the handle to stop it spinning while you undo the hex nut. always worked for me though

[tony27]

is it spinning or locked up

1 of each 

Tony PM sent

Thanks Walter, will either find or make a 27mm nut at work & go from there

[YZ250H]

It's bigger than 16mm - an M16 nut fits the 38mm 125H forks.
I have the tool at home.  If you can wait until tonight I can measure it up.  I know it is a metric nut and I'm pretty sure it is M20.
I have a nut welded on a T Handle and it works really well.

If it is 27mm across flats that would make it an M18.  M20 is 30mm AF.  So now I'm not so sure it is M20 

[Viper79]

The one I made is 24mm...

[curly001]

Tony if there 38mm forks it's a 24mm nut and 27mm for the 43mm forks.

[tony27]

Definately 43mm forks, I fitted a all balls seal kit a while ago & noticed some play in 1 leg at the time but didn't have time to get the bushing kit.
Bought a moose racing set off ebay a couple of weeks ago & now that the season is over it's time to go through the bike properly. Turns out that moose racing is owned by all balls according to the packaging

[tony27]

Managed to get first leg apart today, turns out my forks have a 30mm hex
The damper rods appear to have had some of the top turned off. The hex is about 3mm deep & the head measures 16.5mm high
Any idea what height the head should be so I can look at extending them back to standard while they're apart

[YZ250H]

I think the head of the damper is only very shallow from memory    Just enough depth to get a hold with the tool.
Got a picture ?

[tony27]

No photo, the top looked fairly freshly machined.
Have reassembled them & put them back in the bike as it's sitting in at work & I want to remove the airbox to have a go at making a insert for the lower sidecover mount similar to the rear mount, shouldn't be seen with the sidecover fitted if I do it right
It would appear that the shock needs to be removed to get the airbox out so leaving it at work makes more sense

[YZ250H]

That's going to be a bit tricky.  It feels like the entire bike is built around fitting the airbox first 

[tony27]

Thats what I reckon as well, shows they weren't above using child labour on their bikes, fitting the filter is no fun either