T5oo fork lowers tool

[jasper]

Can anyone tell me what size hex is on the end of the Suzuki T-handle fork removal tool for the T500?

I would like to make my own so I can rebuild my forks.

Thanks

[GreenMachine]

Hey mate... Can't help with your specific question, but I have just rebuilt my T500R's forks without the aid of any special tools at all... They're held to the triple clamps with a bolt at the top and a pinch bolt at the bottom, once they're out you unscrew the fork seal holders and everything falls apart. Is the special tool for pulling them back up in to the triple clamp once you're done? I achieved this with a long bolt of the right thread..

I have some pics I can put up if you want.

Hope this is helpful.

Nick

[jasper]

Thanks for the reply.

I can easily remove the forks from the 3tree, where I'm having trouble is separating the fork tubes from the lowers. According to the manual there is a bolt deep in the bottom of the lower assembly that will liberate the tubes once removed. From my understanding its a hex head but I haven't looked at the manual in a while. I was hoping I could figure out what size it was in order to fashion a tool, but it sounds like you had no problems yourself.

[parksie]

Your not getting confused with the GT500 forks. Seperating the fork tubes on a T500 is done by unscrewing the "outer tube nut" which is located at the top of the bottom outer fork tube.

[titan performance]

We undo them by holding the fork collar in the vice in some rubber to avoid damage.......never had any real problem shifting them, even when the forks look really nasty !

[Suzsmokeyallan]

I leave the front end assembled on the T500 minus the fender, and use one or two of those thick rubber strap type oil filter removers side by side.
Wipe the tube collar and strap with alcohol before use, then cinch it up as close as you can and give it a quick turn. It may take a few tries but it will turn and loosen.
This technique works for the first generation T500 forks dis assembly and even if it slips it wont mark the chrome. Once they are loosened then you can pull the front end down for service.