3en2 damper rod removal tool

[SteveO916]

Hi,

i'm about to change the fork seals on my FZR 3en2.

unfortunatley i do not have access to an impact gun, so i need to make up a tool to stick down the fork to stop the damper rod turning while undoing the bolt.

anyone have any idea what i can make a tool out of to do this? i've heard a long piece of rod with a nut welded on might do the trick? but what size nut??

any other methods?

cheers

SteveO

[thunderace]

I usually crack the bottom bolt off before I undo the fork cap so there's still pressure on the damper rod to help stop it turning.

[SteveO916]

yep i tried that first....no joy..

got the tops off and springs etc out, but can't see clearly what's down the end.

also how much oil needs to go back in. different amounts came out of each leg so can't use that as a guide...

[Evilchicken0]

Wooden broom handle.
Hold it over the nut and knock it down with a hammer to hold the nut - that should be enough to get the bolt turning.

[Phil Norton]

+1 on the broom handle.

That's actually how we were taught to do it at college!

[Hogdigerdy Dog]

there's a good fork overhaul thread below, where they used round bar with the correct sized nut welded on

http://www.fzrarchives.com/ipb/index.ph ... opic=22544

but i used 1/2" square bar as you can put a spanner on it, round is a bit more tricky and needs mole grips pic below



just weld the nut to the bar,
it was trial and error as you can see there's 2 nuts welded on the bar, and another on the bottom before i got it right
it's 29mm across the flats of the nut

EDIT: the 3en2 has smaller diameter forks, so the nut size is PROBABLY different, you'll have to suck it and see

[SteveO916]

forks apart, anyone know the qty of oil that needs to go in 41mm forks on a 3en2? or the air gap?

[thunderace]

523cc or 90mm air gap with springs out and fully compressed for the 41mm forks on the 3EN2

thanks Yamaha workshop manual