Fork caps stuck!!!!!

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.

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.

Do you have access to a vise with padded jaws? If so, maybe pinch the cap in the vise and twist the leg. Ed

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.

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!

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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.

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.

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 ^^^

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!



The things we do for love.



Finally!

Glad to here it worked out.
If u want newer caps try sending kz10006
(Brian) a PM for some used ones.

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