Yamaha fork damper rod Tool, dt125... size?

Jamie S · World Chat Champion Joined: 28 Dec 2006 Karma :

Hi guys, I'm doing a set of fork seals on my 98 dtr125, the problem is the allen bolt that holds the damper rod in is just spinning, tryed using a wooden dowl shapped to a taper and wedged in to hold the rod but won't grip it well enough.
I would be able to use a bolt of the right sized head and weld it to a length of bar to hold the damper from the inside, the only problem is I don't know what size head I would need, does any one know ? (even roughly?) at a guess its looks to be around 20ish mm , but hard to tell as the leg makes it very hard to judge
I'm going to try my impact gun on the allen bolt in work tomorrow and hope this will free it off, if not then looks like im going to have to hunt around and try find a bolt of the right sized head.

Regards, Jamie.

ms51ves3 · Super Spammer Joined: 07 Jun 2007 Karma :

If you put the spring and fork cap back on you should be able to undo it. If not, then you will definitely get it undone that way with a buzz gun.

Blue_SV650S · World Chat Champion Joined: 27 Nov 2008 Karma :

Jamie S · World Chat Champion Joined: 28 Dec 2006 Karma :

Blue_SV650S · World Chat Champion Joined: 27 Nov 2008 Karma :

TUG · World Chat Champion Joined: 12 May 2007 Karma :

Billing · World Chat Champion Joined: 12 Mar 2009 Karma :

When I did my TZR seals all I did was lever my old ones out with a screwdriver, put the new ones in and haven't had any troubles yet Thumbs Up

But I think the haynes manual says you should remove the allen bolt before the spring (Y)
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27cows · World Chat Champion Joined: 01 Nov 2009 Karma :

I always use a piece of dowelling, but I don't taper the end, just tap it into the end of the damper rod. Then get someone to hold the dowelling with a pair of pipe grips/the like while you loosen the allen bolt. There's a special tool you can get - I have one that fits several bikes, but it's too short for trailie forks.

hmmmnz · Super Spammer Joined: 22 Aug 2006 Karma :

try a m12 bolt with 2 nuts (stainless) locked on the shaft of the bolt,
it should be a 19mm nut, tape the bolt into your socket and add extensions untill it reaches the hole
https://i99.photobucket.com/albums/l299/xz550rj/DSCF0162.jpg
https://i99.photobucket.com/albums/l299/xz550rj/DSCF0163.jpg
https://i99.photobucket.com/albums/l299/xz550rj/DSCF0164.jpg
https://i99.photobucket.com/albums/l299/xz550rj/DSCF0166.jpg

if a 19mm is too big try a zink nut (18mm on m12)
still to big try a m10 bolt and nuts ect ect
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chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

The tool from Yamaha was £12 for my TDM damper rods, which isn't too bad you will need a couple 3/8th extender bars though. Puttingin it back together with the spring in didn;t work on the TDM.
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TUG · World Chat Champion Joined: 12 May 2007 Karma :

---- · World Chat Champion Joined: 29 Sep 2006 Karma :

~There easy enough to make yourself...
I made mine out of an old socket and grinder to get it to the right shape,took about 10mins to do. Cant find a pic of mine Sad

I also made the same kind of thing as Hmmmnz said for my gs500,but i used a long length of threaded bar with 2 nuts locked together on either end.
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Jamie S · World Chat Champion Joined: 28 Dec 2006 Karma :

Well, it aint freeing off, 200ltr compressor, 1/2inch snap on air gun, and the spring back in and it did not want to undo, it just span, so I (stupidly) put a bit of wooden dowl down the inside to stop it spinning, which promply snapped off half way down inside the damper, so now I can't even get a tool down there to hold it.
Does any one know how long the allen bolt is?
Would I get away with drilling the head off and removing the rest once the legs are apart with mole grips/stud extractor ect?

---- · World Chat Champion Joined: 29 Sep 2006 Karma :

I'm sure it's only a few inches long at the most.
I can't see any reason you couldn't drill the head off,it won't be tight into the damper rod once the head's off but i would try my best to get that wood out and do it the proper way just incase...

EDIT:
If needed i can go and take some pics of the internals (damper rod/allen bolt length e.t.c.) if it helps?
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Jamie S · World Chat Champion Joined: 28 Dec 2006 Karma :

---- · World Chat Champion Joined: 29 Sep 2006 Karma :

---- · World Chat Champion Joined: 29 Sep 2006 Karma :

chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

TUG · World Chat Champion Joined: 12 May 2007 Karma :

It didnt undo with the spring back in and the fork cap back on?
For future reference you could always just buzz guna the bottom bolt off and drain it before dismantling it.

I dont see why you struggled so much, the hardest part with doing seals on yams (125cc and lower) is the stupid circlip caps, you have to push it down, pry out the circlip then slowly increase spring tention to pop the cap out because it has an O ring around it.
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Mark65 · World Chat Champion Joined: 16 May 2008 Karma :

God bless wizzy guns for fork legs eh lonewolf lol.

Mark
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Jamie S · World Chat Champion Joined: 28 Dec 2006 Karma :

Sorted it, managed to get the wood out and used my spair rear wheel spindle welded on to a bit of bar, perfect size.
Very Happy

TUG · World Chat Champion Joined: 12 May 2007 Karma :