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Clubroom => Tech Talk => Topic started by: Slakewell on February 11, 2012, 04:31:15 pm

Title: Fork cap removal problems
Post by: Slakewell on February 11, 2012, 04:31:15 pm
 I have some 77 YZ forks and I can't get the caps out, I have done the normal things, made sure the forks are well thou the clamps so the clamps are not binding the caps, heat gun etc , I just used the correct size impact 8 sided socket with a stiff wack from the rubber mallet and crushed the hex. Apart from machining them out does anyone have an idea?
Title: Re: Fork cap removal problems
Post by: frostype400 on February 11, 2012, 04:48:43 pm
I have used when my impact driver didn't get them a normal ratchet and a bit of pipe to get a heap of leverage on the ratchet.
Title: Re: Fork cap removal problems
Post by: monaro308 on February 11, 2012, 05:14:37 pm
Try a heat gun on the tube and try tightening them up first and then back them off...if you can.
Title: Re: Fork cap removal problems
Post by: ba-02-xr on February 11, 2012, 06:10:03 pm
Common Mick take of your skirt & have a go ;D.
Title: Re: Fork cap removal problems
Post by: Slakewell on February 11, 2012, 09:38:02 pm
As you would know John most folks bring this type of problem to me , It's normally not my own stuff, I have never seen aluminum stuck in steel as good as this.
I will probably just bore them out .25 over the thread size and then just pull out with left overs.
Title: Re: Fork cap removal problems
Post by: SLAWESY on February 11, 2012, 09:49:55 pm
Slakewell, Try using a six sided socket. It seems to give a closer and more secure fit. You may have to smack the socket on to the cap if the edges have caved in a bit. (you can normally pick one up in a hardware shop). Also make sure that you have completely loosened the top triple clamp bolts. Has worked for me when the caps have been attacked by some heavy handed mechanic.
Title: Re: Fork cap removal problems
Post by: lukeb1961 on February 12, 2012, 04:55:26 pm
I had a '78 PE/RM fork like that about 5 years ago.. one cap undid with a gentle push but the other...
After four nights of failure, ended up putting the entire front-end into a hefty vice, then getting some plumbers stilsons onto the cap head - gave it a good wallop with a wooden mallet for good measure - AND used a three foot bar on the Stilsons...  It promptly moved  ;D

Sometimes excess force is barely enough.
Title: Re: Fork cap removal problems
Post by: chrisdespo on February 13, 2012, 07:39:34 am
Get a shinano 3/4 drive rattle gun not much wont yield to one of these.... ;D
Title: Re: Fork cap removal problems
Post by: Slakewell on February 13, 2012, 08:08:08 am
I have used a six sided impact socket and bar , It has just crushed the nut and turned into mush. Now looking for 38mm Yamaha for caps  ;D