Forks won't come apart

[dkupf]

I'm trying to pull a set of Cr250m2 forks apart. But the Allen head bolt in the bottom of the fork is just turning round and not coming undone. Anyone got any idea's on how hold the internals while I screw the bolt out. Darcy

[HL400]

I find jaming a broom handle in the forks will do the trick and hitting the bolt with a punch will squash the coper washer a little bit to make it easer to undo.  HL

[LWC82PE]

this would have to be one of the most commonly asked questions , im not familiar with these forks but im sure you will get an answer soon. Usually you will need a tool to go down inside and locate on the damper rod to hold it from turning.

[Ji Gantor]

Hi  dkupf,
I also do not know this fork arrangement but a trick that works on bolts that turn is to get a rattle gun set to max speed in the undoing direction and pull the trigger. The bolt is turned so fast that the dampener rod does not get a chance to turn. The rattle gun type is the 1/2 inch wheel nut type.

Ji

[oldyzman]

To DKUPF,
If it is the kayaba type as i have just been working on you look inside the tube you may see something that looks like a female socket (star) which is on top of the danpenner tube. if it is the case then you must establish what size bolt head would fit in it and weld it to a piece of rod. Kind of like an allen key. Someone else may like to expand on this
Brett.

[pokey]

Old bottle jack handle works a charm on yamahas

[Oggy Doggy]

Old bottle jack handle works a charm on yamahas

I can back Pokeys bottle jack method. It works for me on not only Yammy forks but Betors. I'm also not so up with Honda forks but I seem to remember successfully using the bottle jack handle or a long rod with a taper screw driver style edge .
I think XL motorsports have similar forks to the Elsinore. I've tried the trusty old broom handle as well with varied results. It works on outside spring Maicos from memory.

[Mick]

Rattle gun, plus compress forks at same time, works for me everytime.

Cheers Mick.

[mainline]

broom handle up inside the tube, round end first lean on it a bit so it bites in, and away you go

[dkupf]

Thanks alot for all the advice everyone. Tried the broom handle trick and it worked . But now I don't have any brownie points left with the misses. . The sacrifices we have to make to build our bikes  Darcy #674

[mainline]

dkupf, is the CR being restored or is this a maintenance job? It may be my lack of knowledge on the subject but is the 77 model a bit more rare than others?

There was a really nice one (reader resto) in an old issue of VMX, it certainly stuck in my head as a model I could quite happily grab if the chance came along.

[dkupf]

Just a maintenance job.I use mine for a back up bike and everyone else seems to spend more time riding it then I do .I don't know why because I quite like the bike and enjoy riding it. I don't know much about how rare the 77 model is. Darcy

[lukeb1961]

Suzuki had this simple 'prong' to push in and hold the thing. A broomstick is cheaper and just as effective!



T-bar is a 3/8" square drive, about 520mm long.

[LWC82PE]

yes that is my tool Luke just posted. its genuine suzuki and i reckon its the best tool ive ever bought. well worth the money and makes doing the job a lot easier. I got that spike attachement for the TS bikes but ive used it on many other forks from other brands. its actually a hardened tip and does not get damaged the same was as a mild steel home made tip will. for PE forks i made my own tool though and welded a nut onto a length of steel but you can also get that attacment and a couple other different attachements to go onto the suzuki T handle.

[misfit]

my father was a motorcycle mechanic in the 80's working for a suzuki dealership, and has one of those tools. ive made up a few attachments to clip on the end for pulling apart sl and ke forks