GP100 Damper rod not playing nicley

[A100man]

Upgrading the A100 with GP100 forks and a disc brake. Figured I'd change the rotten seals on the donor GP forks., but damper rod not playing nicely and I cannot see any way to hold the rod still other than use 'friction'. Heres a link to the rod I think..

https://www.cmsnl.com/suzuki-gp100-1978-c-e01-e02-e06-e13-e14-e24-e30_model13378/cylinder_5114639140/

So far I have replaced teh spring added a socket for extra preload and
lent on the assembly with all of my 10.6 stome and used an air rattle gun without success.

There are square tapered holder tools on ebay I can buy if people have had success with these or any other suggestion?

Ta
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Now: A100, GT250A, XJ598, FZ750

Then: Fizz, RS200, KL250, XJ550, Laverda Alpina, XJ600, FZS600

[Nobby the Bastard]

Yep. I used a square poker down the leg to hold it still when I had one.
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trevor saxe-coburg-gotha:"Remember this simple rule - scooters are for men who like to feel the breeze on their huge, flapping cunt lips."
Triumph Sprint ST 1050

[Easy-X]

You're talking about the bolt at the bottom of the exterior of the fork that screws into the damper rod?

First up I'd suggest just having the rod and bolt in your hand and wind it in to get a feel for any tight spots, e.g. threads need cleaning. After that reassemble everything else - main spring and end cap on - that should be sufficient pressure. Wind the bolt in with an hex key slowly by hand, again to get a feel for any slipping. If you managed to get it ~90% tight and then it slips an impact driver might help (but I doubt it) and after that you'd have to employ the long rod with the square end.

This is the approach I've taken so far on forks all the way from the '70s to present day.

If you want to make your own tool rather than forking out (hehe) you could either buy a piece of metal rod of reasonable length and file the end or you might get away with hammering a pipe into shape.
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Royal Enfield Continental GT 535, Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter

[Islander]

I've used a whittled down piece of dowel in the past to do this. Necessity being the mother of invention and all that...

[A100man]

Hi folks. Thanks for the tips, this morning I found some 8mm round bar (I dug out of the garden and saved in the that'll be useful one day pile) that I think I can fashion into a tool to loosely resemble this..

https://www.ebay.co.uk/itm/144685234629?

I'll let you know how it goes..
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Now: A100, GT250A, XJ598, FZ750

Then: Fizz, RS200, KL250, XJ550, Laverda Alpina, XJ600, FZS600

[stinkwheel]

Are you trying to get the bolt in or out?

If out, just drill the head off the bolt.

If in, make sure the rod is jammed all the way into the bottom of the slider by screwing a long bit of threaded bar into it and using it as a slide-hammer. I'd also check the threads are in good order.

Leaning on the assembly is unhelpful, if anything you'd ideally want to be pulling the bolt slightly away from the slider so the rod engages in the bottom of it.
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“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[A100man]

[stinkwheel]

I've drilled them before and the puishing down seemed to stop the head rotating too much. The stub that's left has always unscrewed easily afterwards.

You don't need to provide very much resistance to the rod turning for a burp gun to work so a broom handle would probably work, or just keep rattling the fucker until it either undoes or breaks.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[Easy-X]

[Nobby the Bastard]

TBH, sticking a suitably chamfered piece of dowel or similar is the traditionally accepted approach.
____________________
trevor saxe-coburg-gotha:"Remember this simple rule - scooters are for men who like to feel the breeze on their huge, flapping cunt lips."
Triumph Sprint ST 1050

[A100man]

Success! a roughly tapered rod (in this case some bar with a nut weld on the other end) did the trick..

..now skinning my knuckles on getting the damned seals out, heat and small tyre lever tried thus far and it's starting to disintegrate.
____________________
Now: A100, GT250A, XJ598, FZ750

Then: Fizz, RS200, KL250, XJ550, Laverda Alpina, XJ600, FZS600

[stinkwheel]

Wait until you find the circlip groove has totally corroded away and there's no way of holding the new ones in...
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[A100man]

[A100man]

shucks - no clue how to delete duplicate photo
____________________
Now: A100, GT250A, XJ598, FZ750

Then: Fizz, RS200, KL250, XJ550, Laverda Alpina, XJ600, FZS600

[stinkwheel]

Fixed it for you. Aye, that looks a lot better than some of the ones I've seen before.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[Nobby the Bastard]

[A100man]