2003 KX125 Fork disassembly tool

Post by **Sandblaster** » Tue Nov 28, 2017 3:16 pm

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..

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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..

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I only made one tab but you could make all 4 tabs if you wanted.

Post by **Sandblaster** » Tue Nov 28, 2017 3:24 pm

Here is basically what I made with one tab..

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But you could and, may need to make one with more tabs..

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It all depends on how hard it is to turn your valve.

Post by **Sandblaster** » Tue Nov 28, 2017 3:37 pm

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