Fork caps stuck!!!!!

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04 Apr 2012 19:05 #514069 by gwolever
Fork caps stuck!!!!! was created by gwolever
Hey guys. I was going to install new springs in the forks today and couldn't get the damn caps to budge.

I tried a 22mm wrench, a crescent wrench, and even tried what I read somewhere on this site about heating it with a propane torch to loosen it.

None of it worked. Tried an impact wrench, but am having a tough time finding a socket that fits correctly. I would need a 4 point 22mm impact socket and can't find one.

Any suggestions? I am about to give up before I just completely pulverize the caps with failed attempts.


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1982 KZ1000 CSR
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04 Apr 2012 19:51 #514072 by KZJOE900
Replied by KZJOE900 on topic Fork caps stuck!!!!!
Hey Gwolever, did you let it soak in anything prior to you trying to take it off? Just went through a situation (see the thread "Top shock mount") a couple of days ago. Tried penetrating oil but didn't work. I finally used some Marvel mystery oil for an hour or so along with some heat and it finally came off. Might be worth a try.

Current project 76 KZ900 (This was a Vetter model)
76 KZ900
81 XJ550H SECA (Current Project)
82 XJ550R SECA
Past:
86 FJ1200
74 Z1900
72 CB450

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04 Apr 2012 19:51 #514073 by 650ed
Replied by 650ed on topic Fork caps stuck!!!!!
Do you have access to a vise with padded jaws? If so, maybe pinch the cap in the vise and twist the leg. Ed

1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)

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04 Apr 2012 21:38 #514084 by gwolever
Replied by gwolever on topic Fork caps stuck!!!!!
Thanks for the suggestions guys. I don't have a padded vise, but I was using a piece if rubber wrapped around the fork. No matter how tight I got the vise, the caps are on so tight that the fork still slowly moves a little when I put pressure on to loosen it.

I like the vise suggestion with the cap...and I will be trying the soak in Marvel mystery oil as well.

1982 KZ1000 CSR

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04 Apr 2012 23:31 - 04 Apr 2012 23:32 #514110 by Patton
Replied by Patton on topic Fork caps stuck!!!!!
Could try soaking for a day or so in a 50-50 mixture of acetone and atf, which makes an excellent diy penetrant.

Am thinking heat application to both cap and tube may tighten the connection by swelling the cap inside the tube, because the aluminum cap would be expected to expand relatively more than the steel tube. But could attempt heating only the tube section several inches below the cap while simultaneously attempting to twist loose the cap.

Another option is dry ice application to the cap (because the aluminum cap would be expected to shrink relatively more than the steel tube), and possibly combine this with heating the tube, all while attempting to twist loose the cap.

Will a socket fit tightly enough on the cap to allow using an impact wrench?

All of the above after the extended soaking.

Good Fortune! :)

1973 Z1
KZ900 LTD
Last edit: 04 Apr 2012 23:32 by Patton.

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05 Apr 2012 09:49 - 21 Feb 2013 15:36 #514161 by martin_csr
Replied by martin_csr on topic -
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Last edit: 21 Feb 2013 15:36 by martin_csr.

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  • Motor Head
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  • FIX UP YOUR BIKE RIGHT AND CHEAP
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05 Apr 2012 10:16 #514168 by Motor Head
Replied by Motor Head on topic Fork caps stuck!!!!!
You might have to put them back in the tipple clamps, with the caps high enough not to pinch the threaded area. You can make a socket to fit the shape of the cap, out of a piece of flat bar stock, if you don't have a wrench.
Or Harbor Freight has a cheap set of large metric wrenches.

1982 KZ1000LTD K2 Vance & Hines 4-1 ACCEL COILS Added Vetter fairing & Bags. FOX Racing rear Shocks, Braced Swing-arm, Fork Brace, Progressive Fork Springs RT Gold Emulators, APE Valve Springs, 1166 Big Bore kit, RS34's, GPZ cams.
1980 KZ550LTD C1 Stock SOLD Miss it
1979 MAZDA RX7 in the works, 13B...

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  • mark1122
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05 Apr 2012 10:38 - 05 Apr 2012 10:57 #514174 by mark1122
Replied by mark1122 on topic Fork caps stuck!!!!!
i have read that the 50/50 acetone trany fluid the Patton mentioned is the best thing u can use. how about reinstalling them in the triple and using a pipe wrench. u can always replace the caps.

76 KZ, frame gusset work,1200CC.Ported by Larry Cavanaugh, 1.5mm.over intakes, Carron Pipe, ZRX12 rear end, and seat,96zx9 front end.
01 CBR600F4i Track bike.
Cobourg, Ont. Can.

~ ~ ~_@
~ ~ _- \,
~ (k) / (z)
Last edit: 05 Apr 2012 10:57 by mark1122.

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05 Apr 2012 11:02 #514179 by Kidkawie
Replied by Kidkawie on topic Fork caps stuck!!!!!

Motor Head wrote: You might have to put them back in the tipple clamps, with the caps high enough not to pinch the threaded area.


this ^^^

1975 Z1 900
1994 KX250 Supermoto
2004 KX125

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05 Apr 2012 17:54 #514224 by gwolever
Replied by gwolever on topic Fork caps stuck!!!!!
Got em! What a PITA! I let them soak in Marvel Mystery Oil, put them in the vice, put a torch to the tubes, and put the dry ice on the caps. Took a 22mm wrench on and a few hits with a hammer and they broke loose.

Thanks for the help guys!


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The things we do for love.


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Finally!

1982 KZ1000 CSR
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05 Apr 2012 18:00 #514225 by mark1122
Replied by mark1122 on topic Fork caps stuck!!!!!
Glad to here it worked out.
If u want newer caps try sending kz10006
(Brian) a PM for some used ones.

76 KZ, frame gusset work,1200CC.Ported by Larry Cavanaugh, 1.5mm.over intakes, Carron Pipe, ZRX12 rear end, and seat,96zx9 front end.
01 CBR600F4i Track bike.
Cobourg, Ont. Can.

~ ~ ~_@
~ ~ _- \,
~ (k) / (z)

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05 Apr 2012 18:30 #514229 by 650ed
Replied by 650ed on topic Fork caps stuck!!!!!
Glad to hear you got them out! When you put them back together you may want to weld the caps on - that way they'll be easier to remove next time. :woohoo: :laugh: Actually, you may want to put a dab of anti-seize on them. Ed

1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)

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