Fork tube puller tool

Stephen Brenton's purpose made tool

Stephen Brenton used to manufacture this tool. View all of the tools that Stephen Brenton used to make.

Tool threads into top end of fork tube. Affords pulling fork tube up into triple tree during reassembly. See Guzzi Manual, Fig 105, tool 4. MG# 12909500

Tim's DIY tool

Got the forks rebuilt and reinstalled today. I looked on Greg Benders site and saw where he used a special tool to pull the forks back up through the covers. Since I didn't have one I improvised one from a piece of ³⁄₈ inch all thread and some washers. The washers are slightly smaller than the id of the forks with an O-ring sandwiched between. I inserted it into the forks and tightened down the large nut...it expanded the O-ring for a good friction fit. Slid the whole works up through the clamps...snugged down the pinch bolt...removed my homemade tool and got enough threads on the cap nut to secure it...then continued to work the forks up by tightening the big nut...releasing the pinch...and so on until everything was snugged up.

Joe Tokarz's DIY tool

Here is an alternative approach to an already good idea as shown elsewhere on this page. It's a bit more expensive since the expansion plug cost about USD $4.00.

Instead of using a compressed O-ring, I used a hex nut rubber expansion plug (O'Reilly Auto PN 02600). The expansion range is 1 inch to 1.125 inch and since the inside diameter of the fork top across the treads is about 1.1 inch it works great. It will compress more for a really snug fit.

Remove the hardware from the plug and ream out the hole to allow the ³⁄₈ inch rod to pass through with a bit of a push / screw action.

Assemble the tool with some compression on the plug so it grips the inside of the fork tube. Insert to the length of the plug. Then tighten it up. Since there is a lot of contact area it won't pull out by surprise. Install the fork as described before.

An important item not mentioned previously is the importance of the ³⁄₈ inch coupler and jam nut at the opposite end of the rod. It holds the rod from turning so the lower coupler can be unscrewed. I welded a T that holds the rod and eliminates one wrench. Besides it looks more factory.