1995 and Newer KDX Service Manual Owners, Please Read

Post by **KDXGarage** » 07:17 pm Nov 13 2004

Hi. If anyone has a 1995 or newer service manual, can you please tell me what the part number is for the tool to hold the fork cartridge assembly still while loosening the base valve assembly (the bottom of the forks)? My 1995 manual says 57001-1245, but when I tried to order one from BikeBandit last week, they said it was discontinued.

Thank you.

skipro3 · Post by **skipro3** » 11:18 pm Nov 13 2004

Sorry Jason, my manual shows on page 1-16 lower right corner a drawing of a "Fork Cylinder Holder" P/N 57001-1245
Then again on page 11-4 at the bottom is a list of special tools that includes the same item and part #.
I'm useless

Post by **KDXGarage** » 11:31 pm Nov 13 2004

skipro3 wrote:Sorry Jason, my manual shows on page 1-16 lower right corner a drawing of a "Fork Cylinder Holder" P/N 57001-1245
Then again on page 11-4 at the bottom is a list of special tools that includes the same item and part #.
I'm useless

That is exactly what my 1995 KDX200 service manual says, too. My manual states that it covers the 1995 model year. It is part number 99924-1181-01. Does your manual have the same part number? If not, what part number is your manual?

I have the Kawasaki 1988 KX125/KX250/KX500 manual, and the same special tool is listed in that service manual. I also have the Clymer KX manual for:

KX125/KX250 1982 - 1991, KX500 1983 - 1993

It shows the 57001-1245 special tool for the 1988 model year.

I just don't see how that tool could be discontinued unless they came out with a new and improved tool with a different part number.

Thanks for your help, skipro3. I really appreciate it.

Post by **Indawoods** » 11:35 pm Nov 13 2004

Jason... Have you asked your local stealership?

skipro3 · Post by **skipro3** » 11:37 pm Nov 13 2004

yup, my manual has the same Part #. That explains why we have the same info anyway. From the looks of that drawing of the tool, it could be made out a length of all-thread. Maybe you could just make your own? Maybe when CC stumbles onto this he could help. I'm sure he's been down the same road.

Post by **KDXGarage** » 11:42 pm Nov 13 2004

Why? What in the world made you think they would know more than our combined effort? :-)

I am hoping someone with a current or close to current manual will report what their manual says.

A couple of years ago, I ordered a manual for my '87. The guy said it will be here in X amount of days. After time past, I called and the parts guy said it was discontinued. I think they don't know immediately if it is discontinued, because BikeBandit took my order for that tool, but after a couple of days, e-mailed me and said it was discontinued.

Post by **Indawoods** » 11:44 pm Nov 13 2004

I will check with my stealership for ya.. or you could go to their website... http://www.worldofpowersports.com

KA57001-1245 HOLDER,FORK CYLINDER $11.54

Subtotal: $11.54
Sales Tax: $0.00
Shipping: $7.00
TOTAL: $18.54

Post by **KDXGarage** » 11:52 pm Nov 13 2004

skipro3 wrote:yup, my manual has the same Part #. That explains why we have the same info anyway. From the looks of that drawing of the tool, it could be made out a length of all-thread. Maybe you could just make your own? Maybe when CC stumbles onto this he could help. I'm sure he's been down the same road.

Thanks for looking. The two special tools mentioned in the 1987 KDX200 manual are real difficult for one person to use. It is really a two man job. The bolt needs to be tightened to 52 ft. - lbs. of torque while an upside down pyramid is placed inside a round hole, and one has to press down to keep it from spinning. The four sided part that touched the fork internals is avtually a 3/8" socket and the other tool is an approximately 18" long T handle with a 3/8" socket drive end on it.

I just got back from Lowe's. I bought some stuff to try to make a home made tool. I already have the forks bolted back together and tightened down to the correct torque, but I need something different for the next time. I bought an 18" length of pipe that is threaded on each end. I bought a threaded T adapter to put on the top and a approximately 32/33mm nut with machine threads that with a little coaxing, will be jammed / crossthreaded / whatever it takes onto the pipe thread end of the pipe. I am going to have to grind the 6 faces of the nut down to 30mm. I hope it will work.

I am still going to order the 57001-1245 from ronayers.com next week.

I would still like for someone with a newer manual to report what their manual says.

Thank you very much.

Post by **KDXGarage** » 11:55 pm Nov 13 2004

Thanks, Indawoods. I think that site is just like BikeBandit, where they don't have 4,000,000 parts in stock. They just order it and hope for the best. I don't think any of these online places maintain the inventory. They are just like a dealer. They may have a few things in stock, but none of the old or odd-ball crap I want. :-)

Post by **Indawoods** » 11:57 pm Nov 13 2004

Well... they are right down the street from me... and they are BIG! I will pop in there tomorrow if they are open and find out for ya....

Post by **KDXGarage** » 12:26 am Nov 14 2004

WOW. You are lucky that they are close.

If / when you ever go by and want to ask them about it, that would be great.

Thanks!

fulltiltboogie · Post by **fulltiltboogie** » 05:43 pm Nov 14 2004

You really don't need any speciasl tool. You can use an impact to take out the valve. Leave fork assembled, turn upside down and slightly compress tube and use your impact and it will come right out.

Post by **KDXGarage** » 06:37 pm Nov 14 2004

fulltiltboogie wrote:You really don't need any speciasl tool. You can use an impact to take out the valve. Leave fork assembled, turn upside down and slightly compress tube and use your impact and it will come right out.

I have an '87 KDX200 and a '94 KDX200. The manuals do not mention the 57001-1245 tool. They mention different tools. I am just trying to figure out if the 57001-1245 tool is discontinued or not, as I was hoping it would work on my '87 forks. I tried to order one from BikeBandit and they said it was discontinued.

Thanks for the suggestion on the air impact wrench. I have seen several people mention using an air impact wrench. On the pre-'89 forks, it is actually just a bolt. There is no base valve assembly. I would still need to tighten it to the proper torque on reassembly, so I think some tool is going to have to hold the damping rod still during reassembly. I bought an air impact wrench last night, so I am going to use it next time during disassembly. Paul Thede used one on the Race Tech video, and it seemed to make it a LOT easier during disassembly.

Thanks.

Post by **Mr. Wibbens** » 11:08 pm Nov 14 2004

I tried making the tool listed here and at the other site

But I had trouble finding a metric nut that large

I ended up buying FRP's Fork Dampener Tool

Post by **KDXGarage** » 12:23 am Nov 15 2004

Mr. Wibbens wrote:I tried making the tool listed here and at the other site

But I had trouble finding a metric nut that large

I ended up buying FRP's Fork Dampener Tool

HEY! :-)

Isn't the FRP tool a pipe with a nut on each end?? What size are the nuts?

Thanks!

Post by **Mr. Wibbens** » 12:29 am Nov 15 2004

According to this: http://kdxrider.net/forums/viewtopic.php?t=40

its a 27mm

I burned up enough gas looking for a 27mm nut that I prolly have close to $50 invested in mine

Post by **KDXGarage** » 12:33 am Nov 15 2004

Are both nuts the same size on your FRP tool?

Thanks.

Post by **Mr. Wibbens** » 12:41 am Nov 15 2004

JasonWho wrote:Are both nuts the same size on your FRP tool?

The nut on the other end is smaller, so you can attach your 12 point socket to it

Post by **KDXGarage** » 12:50 am Nov 15 2004

Well, crap. So, no way it is 30mm, huh?

The soulless batards at Craftsman don't make large 6 point metric sockets, so yes, I DO have a few of those >11,<13 point sockets.

24mm, 27mm and 30mm

:-)

Post by **Mr. Wibbens** » 01:02 am Nov 15 2004

Ok I went out in my underwear and checked it!

The nut on the other end is a 1-1/16"

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1995 and Newer KDX Service Manual Owners, Please Read

1995 and Newer KDX Service Manual Owners, Please Read