Do I need a special tool?

Discussion specific to the 1995 - 2006 KDX200 (H Series) and 1995 - 2005 KDX220R (A Series) models sold in the USA
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hoosierKDX
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Do I need a special tool?

Post by hoosierKDX »

95 kdx forks and I can't get them to separate. Do I need that FRP tool?

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KDXGarage
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Re: Do I need a special tool?

Post by KDXGarage »

Hello from the bar!

Yes. You need to remove the compression adjuster assembly. Hopefully, you have not tried to slide hammer them apart, yet. If so, the bushings are probably damaged.

After removing the compression adjuster assembly and then cartridge, boil up a couple of gallons of water and pour it over the seal / bushing area. It will cause it to expand a little and be easier to separate with less damage to the bushings.
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hoosierKDX
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Re: Do I need a special tool?

Post by hoosierKDX »

Thank you for the response. Yes, I've tried to slide hammer it out, but I'm replacing the bushings and seals.
canamfan
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Do I need a special tool?

Post by canamfan »

Did you remove the compression adjuster from the bottom of the fork? It's a 14mm allen, usually an impact wrench will get it out otherwise you have to have the special tool or make one like I did.
hoosierKDX
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Re: Do I need a special tool?

Post by hoosierKDX »

I tried and it just spins..... ordered the tool from FRP off-road......it's almost been a week and I'm still waiting for the tool...... their shop is only 4 hours away from my house.... :hmm:
kenpowell
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Re: Do I need a special tool?

Post by kenpowell »

This trick will usually allow the compression adjuster to be removed.
1. Turn the fork upside down and stick the axle into the fork lug for additional leverage
2. Apply your weight to the axle and push downward - this will push the spring against the damper rod to keep the adjuster from turning
3. Use an air impact driver to remove the adjuster.
Ken Powell
2012 KTM 300 XC with YZ SSS cartridges in the WP tubes
2003 YZ265WR with 2005 AOSS forks
2003 KX125 / KDX200 motor with YZ SSS forks
First Motorcycle - 1963 Harley 175 Scat
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