Stuck fork caps..now with stuck seals

[Doc]

Houston we have a problem! I've a pair of RM250z/d forks I seriously wish to dismantle but the previous owner/s have really butchered the fork caps and I simply cannot move them. They are the hollow air cap type hence the hex part is far from being hex anymore so regular sockets or spanners are as good as useless.. Does anyone know any little tricks that may help in removal of said caps? I have a small pipe wrench  that may work if I really persist but in doing so I feel I am being butcherous..I have a pair of replacement caps ready but getting the old ones to move is the problem..any ideas?? and no! I don't want to buy a honda!   

[pokey]

Id  prolly grab the hacksaw  mate and saw a nice crisscross into the tops and  find a piece of plate  that slips in nicely and use it like a huge screwdriver .  That should budge them. If you can "Make" a large phillips head  you can get twice the leverage and twice the contact point

[mx250]

I'm visualising  ; but, notch them with an angle grinder, insert flat bar and turn  .

[Lozza]

If you have replacement caps just drill 2X5mm holes tap to 6mm,put 2 short bolts in ,over one bolt put the ring of a big shifter and turn. 

HTH

[Doc]

Thanks guys! Pokey I actually went back to the garage and tried exactly the method you stated..actually I am still in the process of grooving but by all intent and purposes it looks like it might just work Lozza your idea is now classified as plan B..plan C is abort the mission 

[Doc]

Shear bliss at Suzuki Central as Plan A works!! looks very ugly but eh, I'll keep 'em on the shelf for spares cause you just never know 

[pokey]

"Ochams raiser"

Why make something more difficult than it need be   

 Great stuff mate.
 dont forget i still have a pair of PE forks with your name on them.  , I can drop them over  sunday arvo on my way back down from  caloundra if  you like.

[Doc]

Actually I did forget!  Sunday works for me  maybe by then I'll have a second problem sorted..getting the bloody wiper holder and seal out of the lowers with the inner still in..I had to give up for tonight as I was losing it  I know it's persistance that is required as I have done plenty before but I just thought maybe, just maybe there might be some ground breaking new 'easy' method I didn't know about

[pokey]

Thats Next sunday mate i should have said,  am working tomoz.


 
Id be dropping the leg to get it out and save whats left of my sanity  if any does still exist, then locating my ergonomically bent screwdriver. If they dont  pop out after the circlip is removed after a few pumps  i call it names then drop the leg off.

[Doc]

no worries bloke! I reckon it's gonna take me till next Sunday to do the forks anyways! The legs are off, I find an old triple holds them better than clamping in a soft jaw vice I'll get back into it today after I've had my Weeties™ 

[oldfart]

Doc
       The fork tube SHOULD remove the seal and wiper when removed unless others have removed the C ring at the bottom .

[Doc]

yeah that's what I figured oldfart but she has not moved a fraction of a mm even with a little heat involved    I figured a few good pulls on the inner with the retaining bolt and snap ring removed should pop out the lot but alas, it is not to be..zee most stubborn fork seal I have ever come across 

[oldfart]

Doc
       Wrap some duct tape around the alloy -stand  upright form a good seal then pour some brake fluid and let it sit overnight and see if that works  ;)works for me

[Doc]

no probs Oldfart, sounds like a pretty good plan, I'll give that a go and attack it again tomorrow you'll hear me from home if it's successfull and if it's unsuccessfull you'll hear me from Sydney 

[Doc]

  oh poo!..well Oldfart, I took your advice and let the seal wallow in brake fluid for near 24 hours and guess what?  the seals are still as stuck as ever. Someone from the Yahoo RM/TM group recommended using the same method but trying carb cleaner instead so I'll have to give that a go now  I have NEVER seen such stubborn seals in all my born natural  any other ideas? I've tried yanking and yanking, I've added heat to the equation, I've now tried brake fluid..I feel plan C is now imminent unless the carb cleaner works  :'(