Kawi fork cylinder holder tool 57001-1406

[KenC]

Apparently I need this tool to get my forks apart (2007 Kawi ZZR600).

Anyone have one or know of an alternative hack ?

I did manage to crack the bottom Allen bolt loose (before fork disassembly), but she's just spinning the inner cylinder now.
I did put it all back together to introduce some tension via the spring, but that's a no-go.

 

[GreyGhost]

Interesting. What does the top of the cylinder look like (the location the tool indexes on). I suspect you could make a tool but cant provide much guidance without seeing what the tool is supposed to hold on to.

Edit:
As this is disassembly, I would probably use an impact. Inertia normally lets each hit make progress. I'd want something with more control for reassembly.

 

[timtune]

I've made a few of those fork tools for other, older bikes. The Clymers manual would often describe the home made version.
As I recall it was some thing like a nut or a socket welded to some length of rod.

If you check the partzilla to get a look at the part your removing it may help to fab something.

That said the picture seems to show the tool being hollow. Perhaps something welded to the end of the right sized tube?

 

[Ash]

I vaguely recall making a tool for this purpose, but can't remember exactly what bike it was for. I have a feeling that I made it out of metal electrical conduit, and just roughly shaped the end of the tube into a hex shape with a vise. It doesn't have to be very precise.

That specific model of holder apparently looks like this (aftermarket): 570011406: FORK CYLINDER HOLDER Kawasaki - buy the 570011406 at CMSNL

 

[timtune]

Looks like the "driver" end is square. A large bolt ground square welded to a length of tube should do it.

 

[GreyGhost]

Looks like the "driver" end is square. A large bolt ground square welded to a length of tube should do it.

Or metal conduit in a vise if you don't have a welder. Dimensions would make this easier. Ideally, that square is a standard size socket extension so no special tools would be required.

A square is a good shape for the op. A large flat head screwdriver in the square may be good enough.

 

[KenC]

As Murphy's law goes, of course after posting I found what looks like a good write up @ https://www.kawiforums.com/threads/fork-seal-replacement.99425/ even thought I wore out Google that last few days searching lol.

Using an impact and 3/4" tubing is mentioned (and also mentioned here)
I'll give the impact a shot this morning and if not then pick up some 3/4" tubing from Home Depot see where that gets me.

You can see how the 3/4" square tubing sits inside the lower cylinder which allowed cranking on the Allen bolt.

Thanks to all for the posts and help, other people's insights and recommendation often get you out of "tunnel vision" on a task