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Old 01-16-2009, 08:10 PM   #91
DisTech OP
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Joined: Sep 2008
Location: Seattle
Oddometer: 616
Damper Rod tool

The DR650 manual lists a couple special tools for getting the damper rod out of the fork tubes:
  • 09940-34520: "T" handle
  • 09940-34592: Attachment "G"
Over in the DR650 thread eldavo references and links the Suzuki DR650 Wiki that explain how to make your own tool. Basically it's a 30mm allen. On the wiki they used a 3/4" bolt that has a 28.3mm head. I found that a nut for a 20mm bolt actually is 30mm. I used that nut a 1/2" bolt, 1/2" nut and a 1/2" nut with the nylon insert. $5 from the hardware store. I used the nut with the nylon insert because the cone shaped end forced the 20mm nut to center.

1/2" nut take a 3/4" socket.

30mm allen nice fit.

The Race Tech Cartridge Emulator instructions for removing the damping rod had me kind of freaked out, "Take the fork off the bike and disassemble them. An air impact and a long Allen socket helps a lot. For stubborn Damping Rod Allen bolts use a drift and beat on the head of the damping rod bolt to jar the threads loose...". Sounds like I'd be using again. I didn't have any problem. Then damper rod allens were tight, but came right out.
DisTech - Suzuki (1993 DR350S & 1994 DR350, 1996 DR650/DR790), BMW (1999 R1100GS)
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