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As the title says. Everywhere I search only gets me the inner fork dimension of 49mm, but I need to know the dimension of the lower portion that the top inner fork compresses into. My best measurements get me 56.6mm. Image showing what I'm talking about. Anyone know?
kevvyd posted a topic in WR400F/426F/450FIn an effort to redeem myself from dredging up an 11 year old thread yesterday I decided I would contribute some much sought after info to this forum. I am in the midst of a complete tear down and refresh of an '07 WR450. I started with the chassis, bearings, wheels, and suspension--and will work my way into the motor last. I am currently re-springing, sealing, and valving my fork, as the prior owner was much heavier and had it set up for him. All is smooth and easy until I get to removing the base valve (compression) to release the damper rod from the lower fork tube. In the past I had luck just shooting it with an impact and the assembly would be free. Not on this fork.... So I set about ordering the Motion Pro damper rod fork tool (Part # 08-0117) BUT that tool only works on 47 mm and under forks. The WR is 48 mm. And of course there is no chance of a dealer having the OEM Yamaha tool--or me paying the exorbitant amount for that piece of tooling. (OEM part #'s 90890-01494, YM-01494) Then it is off to the forums and Google to try and find some answers. I discover that many, many, bro's have asked about what tool to use, or a DIY trick such that they can remove the damper tube and base valve. Many suggest that having the fork leg fully assembled, with springs and all, then loading the upside down leg and shooting it with an impact driver will release the base valve from the damper tube. I definitely believe this and many report having success with that method, though it often requires an extra set of hands. I aint down with that....especially when it comes time to put it all back together and I am going to want the tool to assure that assembly is torqued to spec. So I set off to Home Depot with a fork lower, and my 2 year old. First to the plumbing aisles. First the kitchen and toilet stuff, no luck there. Then into the pipe aisle, 1-1/4 black, or galvanized pipe looks really close but the OD is too big. Time to get creative. Think about what other applications around the house use tubing, or pipe?.....preferably thin walled. Immediately I head to the closet and storage/shelving aisle....thinking clothes hanger rod. I take the 72" piece of decorative pipe and stick it into the fork leg in my cart, while the 2 year old amuses himself with my vernier caliper. Booyah, lets take this to the register, search over. I am very confident from eye-balling it that I can make the tool from this piece of closet hardware! I take the 72" piece and use a pipe cutter to chop off a 12" section from the end without the label sticker or barcode. (shit, I may just return it doubting the clerk is gonna measure) From that piece I make a trace of the OD of the 1-5/16 closet rod circle end. Then I divide the tracing up into equal parts by drawing a tic-tac-toe, or hashtag #### across it. Mark off 4 of the "boxes" on the end with black marker, and use a hacksaw and cut off wheel to remove all BUT the marked pieces. Leaving me with 4 prongs that resemble a "castle". Clean it all up with some filing, and grinding. Then I bored a 3/8" hole through the non-castle end to pass a piece of rod through to use as my handle. I fish the homemade tool around for a second, and it locks right into place! Then while holding the tool I shoot the base valve, 14 mm allen, with a cordless impact and it comes right out. I can't say for sure...but I do not think it was very tight and a "regular" hex wrench or allen socket would work just fine. Also I decided to take some measurements of the damper tube and its tooling receptacle should anyone ever want them. The outside diameter of the tube that protrudes above the flange for the removal tool is ~28 mm The 4 slots that the teeth of the castle tool will fit into are about ~15 mm The distance between the tool slots, when measured on center of 2 parallel holes is ~30 mm The inside diameter of the lower fork leg is ~46 mm It took me 45 minutes in the Depot to look, 20 minutes to fabricate the tool, and the material cost about $20. I have enough left over closet rod to probably make 7 more of these things! If I don't return the remaining 60" to the store...PM me with your address and like $6.10 shipping and I'll cut you off a piece! LOL I really hope this helps many people, and let me say...I can't believe how easy and well it worked! Check out the pics for clarity. You're welcome...