I'm sourcing everything I need to do a seal change. I'm pretty happy with everything apart from damper rod removal, it seems like it's one of those bits that either goes well or turns into a nightmare.

I don't have access to air tools, and I'm not so keen on the broom handle idea.

Does anyone have any pictures of the top of the damper rod? can any sockets be used? what are my options? I see Yamaha do a special tool but can't find much on it and what I have founds suggests it'll be exspensive.

The Inside Diameter of the Tenere damper tube is 18mm. If you chase up a meter of 20mm diameter aluminium rod and have someone turn a 1.5 degree taper in a lathe. Start the taper at 16mm...should work out fine..

Then simply a matter of drilling a hole through the other end to make a T.

Doing something similar with a broom handle also works, providing the the taper is even.

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Attitude is the difference between an Ordeal and an ADVENTURE

Broom handle technique works for me.

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can you tell me more about the broom handle method?

Basically you shape the end of a broom handle into a cone/point, not sharp but say 10-15mm across at the sharpest bit. With the springs removed, insert the broom handle pointy end in first. Rest the bottom of the fork leg on the floor (on a block of soft wood or rubber mat to protect it), then tap the broom handle down into the fork leg with a mallet and onto/into the top of the damper rod. The conical end of the broom handle will shape itself to fit the top of the damper rod. You can then use the broom handle to hold the damper rod in place whilst you crack the nut on the bottom.

Another little tip: If you soak the tapered end of the broom handle in water for a few hours before hand, it softens the wood and lets it mould much better to the top of the damper rod and require less of a whack to get it to seat.

You can sort of see the idea (from about 3:45) in this guy's video of a DR650 fork seal change...

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thats brilliant cheers, i'll give that a go.

The DR looks nice, shame we don't get those in the UK