August 20, 201511 yr Just thought I'd add a picture of the tool I made up to help in the disassembly of the forks. There is an allen key in the bottom that holds the damper rod in place and this is not always straightforward to undo/do up as the damper rod can spin along with the allen bolt. Luckily there is a slot machined in to the top of the damper rod (marked "C" in the picture) and I used this, along with the tool, to stop it from spinning whilst undoing the allen key. You may be able to use a long screwdriver for the same but if you don't have one... read on. I used a bit of steel rod about 18" long that I had lying about (tube would do at a pinch so long as it fits inside the fork stanchion). I then cut/hacksawed a slot in it and made up a bit of flat bar (about 1.5mm thick) to (snugly) fit in the slot. I then ground it to the approx dimensions in the pic. It's the chamfer between the two diameters that locates in the slots in the damper rod. The protrusion of the smaller diameter is just there to help locate it. (and so is much better than a screwdriver). Anyway, it fitted in a treat and did the job perfectly. As it happens I used a bit of stainless for the insert because it was the first thing I laid my hands on. You will need something fairly hard or it may bend. Took about 10 mins to make and I now have a handy arrow if anyone tries to nick my bike wink emoticon
August 20, 201511 yr My first thought was that you dug a tool up from the iron age. Just kidding, nice job.
August 21, 201511 yr Looks like that would do the trick, I have always put the bike on the trailer and pulled down the front end as far as possible and this puts enough pressure on the damper rod to allow the allen headed bolt to be loosened or tightened as required. That tool is certainly easier to use however. Cheers Greg
August 21, 201511 yr Air tools have been affordable for the home mechanic for several decades. My 60 gallon air compressor has been one of the best buys I ever made.
August 21, 201511 yr Air tools have been affordable for the home mechanic for several decades. My 60 gallon air compressor has been one of the best buys I ever made. Sometimes people use Loctite on the threads of the bottom screws, and a rattle gun will not undo them using the inertia of the damper rod alone - the damper rod needs to be held stationary
August 21, 201511 yr Author Also, regards air tools (or battery operated rattle guns for that matter). Great for undoing, but I don't really trust them for doing things back up. Too easy to strip threads. Nothing quite like the feel you get if you do it by hand.
August 21, 201511 yr I have a long magnetic flat driver but you need 2 peapol 1 to hold the driver tight why ther other undose the Allen bolt. Sometimes the slot on the damper can be rusted up. i do have a powered compact driver but normaly only use it for undoing the Allen bolt.
August 22, 201511 yr Sometimes people use Loctite on the threads of the bottom screws, and a rattle gun will not undo them using the inertia of the damper rod alone - the damper rod needs to be held stationary Glad I never came across the fool that uses Loctite. I have done hundreds of forks through the years and never used the so called special tools. The one that gets me is the gorilla that over tightens the fork cap. Which I usually put on hand tight. That way I know if someone else has been into the fork leg since I worked on it.
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