Removing compression bolt assembly on USD forks

Questions and comments about converting to beefier forks..

Removing compression bolt assembly on USD forks

Postby KDX220PHIL » 11:44 pm Dec 30 2005

I am cleaning out my KX forks and trying familiarize myself with the new to me setup.
What is the trick in removing the compression bolt, do I need the special damper rod holder tool, can I use an impact wrench carefully? The idea of the impact wrench seems a ltitle harsh not for taking off but for putting back together. Has anyone tried cutting notches out of a piece of pipe and using that as a damper rod holder tool?
Any tricks or help is appreciated.
Thanks.
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Postby Indawoods » 11:47 pm Dec 30 2005

All you really have to do is turn forks right side up (that's USD :razz: ) compress them and then use the 14mm allen on the impact wrench and using short bursts until it comes loose, then take it the rest of the way off by hand.
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Postby KDX220PHIL » 11:50 pm Dec 30 2005

Compress them? I have the them apart, everything is apart except the bottom.
Should i put them back together to get them apart :shock: .
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Postby Indawoods » 11:50 pm Dec 30 2005

Yup... unless you have "the tool"

You have the cartridge out???
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Postby KDX220PHIL » 11:52 pm Dec 30 2005

Nope, cartridge is still in there.

Crap. Going to try a notched piece of pipe first, if that doesnt work i'll put em back together. :neutral:
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Postby KDX220PHIL » 10:19 am Dec 31 2005

Does it take a lot of force to hold the damper and to remove the compression bolt?

Trying to determine what thickness of pipe I may need.
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Postby Indawoods » 11:15 am Dec 31 2005

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Postby KDX220PHIL » 11:35 am Dec 31 2005

Yeah I forgot about that, it is pretty much identical to the maual I am reading. I skipped the part where it says to remove the compression bolt assembly and I moved on to the seals. I do not see how removing the compressio bolt assembly before removing the seals makes a difference, If i were just changing seals I don't think I would bother removing the compression bolt, but for cleaning purposes and curiosity I must get in there.
Judging by the pic, it doesnt look like it takes much force to hold the damper rod in place afterall, this skinny mechanic can do it single handed :grin: .

Thanks Inda.
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Postby canyncarvr » 09:51 pm Jan 06 2006

I hope you don't (at the time written) have the cartridge out. That's what the base valve screws INTO, ain't it?

Well, the push rod and cylinder is what I'm calling the 'cartridge'.

Anyway...my point is this: You don't have to fully reassemble the thing to get the pressure you need on the inside to get the valve out. Pretty much just the spring with its guide, turn in RSU, hit it with 'The Gun!'

Not that any of it matters. Since 12-31, I'm sure you got it all done by now!

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Postby KDX220PHIL » 08:03 am Jan 07 2006

Problem is that I already removed the fork tube and seals etc. So i did not plan on reassembling it without the new dust and oil seals.
Are you saying that i would not require the upper tube assembled either?
Made one of these instead:

Image

No, cartridge was not out.
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