I have never worked on 03 KX125 forks before.
So it wasn't too surprising that I needed a tool that I didn't have.
The issue is when you go to remove the bottom fork valve and it spins and spins
What you need is a tool that slides down into the fork tube and locks into the slots at the top of the internal cylinder in order to keep the valve from spinning..
So what I did was go down to the local Home Building warehouse and picked up a piece of 1" schedule 40 pipe.
Then I took a piece of 1/8" flat bar and bent it around the OD of the pipe.
Next, I cut the rounded piece of flat bar to the slot length that I wanted.
Once done with that I welded the piece I made to the pipe.
The rest was grinding the pipe and welded on pipe until if fit.
I had to grind the ID of the pipe a bit which took the most time but it's doable even with a dremel tool.
After a few tries of different bits I used a diamond grinding bit..
I only made one tab but you could make all 4 tabs if you wanted.
2003 KX125 Fork disassembly tool
- Sandblaster
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2003 KX125 Fork disassembly tool
If bikes are for kids I'll never grow up.
- Sandblaster
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Re: 2003 KX125 Fork disassembly tool
Here is basically what I made with one tab..
But you could and, may need to make one with more tabs..
It all depends on how hard it is to turn your valve.
But you could and, may need to make one with more tabs..
It all depends on how hard it is to turn your valve.
If bikes are for kids I'll never grow up.
- Sandblaster
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Re: 2003 KX125 Fork disassembly tool
1" schedule pipe is suppose to be:
OD 1.315
ID 1.049
Wall thickness 0.133
But yours will likely vary some due to manufacturing tolerances.
Here is some dimensions for the Inner cylinder slots
OD 1.315
ID 1.049
Wall thickness 0.133
But yours will likely vary some due to manufacturing tolerances.
Here is some dimensions for the Inner cylinder slots
If bikes are for kids I'll never grow up.
- Sandblaster
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- Joined: Thu Jun 07, 2012 3:50 pm
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Re: 2003 KX125 Fork disassembly tool
Here is the dimensions of the tool I made..
If bikes are for kids I'll never grow up.
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