Build your own KDX fork cartridge holder

A service reference
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dsedam
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Build your own KDX fork cartridge holder

Post by dsedam » 10:14 pm Feb 17 2014

So, after a many a read on several sites and trying to track down a cartridge holder tool, I made one for under $12.

Here is what I used all from a local lowes:

1 - 1/2" x 30" iron pipe
https://lh4.googleusercontent.com/-vjBS ... 165903.jpg

1 - Lfa-668 brass garden hose adapter.
https://lh4.googleusercontent.com/-hstn ... 165844.jpg

The brass was used for a couple reasons -
1. It's soft and your reaching aluminum...
2. Easy to grind with a file for deburring...

Screw the adapter onto the pipe as tight as you can, you can even lock tight it on, I did not.

Using a grinder, cut off the excess threads, making flush the brass "nut" and iron pipe.
https://lh6.googleusercontent.com/-doXy ... 170008.jpg
https://lh5.googleusercontent.com/-aX9X ... 165820.jpg

Deburr the cut and the edges of the nut portion of the brass.
https://lh4.googleusercontent.com/-33jr ... 165827.jpg

Clean the internal span of the pipe, you never know what goodies are in there and it will keep you from potentially scratching your damper rod. Wrap the first 20" or so in electrical tape as it keeps it nice and soft for the metal components touching each other...

Finished product:
https://lh5.googleusercontent.com/-99Tq ... 165810.jpg

Insert the tool over the rod and down into the cartridge, lining it up and you should feel it lock in. Using a 14mm allen socket , found at auto zone in a 3 pack 12mm, 13, mm, 14mm for $12, unscrew your valve.

Dan
New to me 2004 KDX 200
Previously owned 1994 KDX 200
Dan
---------------------------------
2004 KDX 200
1994 KDX 200
---------------------------------

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Gotanubike
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Build your own KDX fork cartridge holder

Post by Gotanubike » 11:50 pm Apr 20 2014

Great post, how did you figure a garden hose adapter fits the ARP 12 notched fitment on the damper rod? That adapter is imperial.
1990 KDX200
Bike Profile -> http://www.kdxrider.net/forums/viewtopi ... 61#p136315
Suspension Overhaul(Shock+89-92 conventional forks) -> http://www.kdxrider.net/forums/viewtopi ... 15&t=15255
96'-98' RM125 Showa 49mm fork swap -> http://www.kdxrider.net/forums/viewtopi ... 04&t=16994
KDXrider world map! -> https://www.zeemaps.com/map?group=186158

dsedam
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Re: Build your own KDX fork cartridge holder

Post by dsedam » 03:26 pm Apr 23 2014

At my lowes the pipe and brass fittings are right across from each other. I knew I needed a soft metal and the brass fittings fit the bill. Bought the nearest size, a little grooming and voila...
Dan
---------------------------------
2004 KDX 200
1994 KDX 200
---------------------------------

sthutch
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Re: Build your own KDX fork cartridge holder

Post by sthutch » 04:10 pm May 07 2020

Dan,
I gotta say THANK YOU!!! I haven't ridden in a couple years due to loosing my hearing (and balance) in my right ear. Finally, I feel confident in my ability to ride so I pulled my KDX out of storage to get ready. When I put it away I knew I had a leaky fork seal, so that was the first thing on the agenda. A quick search here yielded the tool I needed, and how to make it. Since this was an older post, I did an online search at my local Lowes for the adapter to make sure they carried it. They didn't carry it, but Home Depot did! I went and picked up the parts, followed your steps and presto, had my tool. It worked perfectly!!!

Thanks for posting this!
Sthutch
Sthutch

1st Bike: '72 Arctic Cat Whisker (rode it to the wheels fell off)
2nd Bike: '76 KT250 Trials (gone, but not forgotten)
3rd Bike: '01 KDX200
4th Bike: '96 DS80 (okay, my 9yr old's and it's gone)
5th Bike: '04 RM65 (okay, he's now 10 and it's gone)
6th Bike: '08 KTM 105xc (okay, he's now 13)
7th Bike: '06 KTM 200xc-w (okay, he's now 16)

pumpguy
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Re: Build your own KDX fork cartridge holder

Post by pumpguy » 03:13 pm Dec 11 2020

Would anyone be able to post pictures of parts used? At this late date those originally posted are no longer available.

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