1995 and Newer KDX Service Manual Owners, Please Read

[KDXGarage]

That's 26.9875mm. Are they both the same size??

Wait a minute. What the heck are you doing with a tool marketed for 1995 and newer KDX's?? Does one end fit your 1992 forks? You do have the stock forks, right? You didn't upgrade to '95 and newer forks did you? I know you have a lot of good mods to your E model, but I don't remember a fork swap being one of them.

Thanks.

[Mr. Wibbens]

That's 26.9875mm. Are they both the same size??

Uh , no, I thought I already answered this .....?

Went out in the cold and checked again..... One end is positively BIGGER than the other! 1-1/16 socket won't fit on other end

Wait a minute. What the heck are you doing with a tool marketed for 1995 and newer KDX's?? Does one end fit your 1992 forks? You do have the stock forks, right? You didn't upgrade to '95 and newer forks did you? I know you have a lot of good mods to your E model, but I don't remember a fork swap being one of them.

Thanks.

Nope, still have the stock forks but the tool works on my '92

I emailed FRP a couple times asking whether or not it would work on my bike, but he never replied
So I just took a chance and it worked!

If you member......? At that other site.... I even took my forks to a shop to have the seals done but they did not have a tool either

[KDXGarage]

Thanks for the info.

I don't remember your post on the fork tool. Sorry.

I have got the tools mentioned in the manual, but they are a bitch for one person to use when tightening the bolt to the proper torque. Don't feel bad about not having them. :-)

I've got a set of 1990 forks. I will get round to dissasembling them one day and see what size the indentions are on the damping rod.

Thanks again.

[KDXGarage]

I just called him. He said it was 27mm and 30mm.

[Mr. Wibbens]

FRP's tool is easy to use

So I guess this tool's design is a little flawed!
http://kdxrider.net/forums/viewtopic.php?t=40

[KDXGarage]

Nah. The tool mentioned on this site just has the 27mm nut, which is correct for the 1995 and newer bikes. Since you said the 30mm nut side worked on your bike (it was the bigger side, right?), then the FRP tool is good for 1986 and newer, except for the USD forks. I don't know about the '85 and older internals.

FRP just shows it as for use on '95 and newer, for some reason.

When I asked him what size the nuts were he laughed and asked if it was so I could make my own tool.

[Northern KDXer]

Mr. Wibbens didn't you see the 1.063" ~ 1 1/6" measurement on the diagram from the other site? I just made one of these tools and that nut was extremely easy to find, I just brought my calipers to the store and measured a couple 1 1/6 nuts.

Where's the other site the diagram came from?

***DOH... damn marauders! *** Indawoods
No more guest posts!!!! Just register... IT'S FREE!!!!!!

[KDXGarage]

Follow-up. Just to make sure, I tried again (Feb 2005) to order 57001-1245 from BikeBandit and they said it was discontinued. :-(

[DirtRoller]

You looked in your underwear and it's only 1-1/16 long.
Jason, are you making this tool or are you looking to buy it? Sounds easy enough to make. I could make it for $25... cover parts/shipping.
If I had one made already, I let you use it for nothing.
The one end could be any size you wanted above 3/4.

[KDXGarage]

I was hoping to just buy the Kawasaki brand tool. Apparently, it is discontinued. I made one for 1986 - 1992 KDX200 forks, but it was a big hassle. Thanks for the offer, though.

[KDXGarage]

I now have an FRP tool and one side is 27mm, and one side is 30mm. It works great. For anyone looking to make their own for 1995 and newer KDX forks, the tool HAS to have a hollow rod. The 1986 - 1992 KDX200 forks do not. The 27mm side is for 1995 and newer. The 30mm side is for 1986 - 1992.

I used to be pretty confused on that tool, so maybe this will help someone else out.