TOPIC:

Hi all, I'm trying to change the fork oil of my '80 KZ750 E1 and have run into a snag. I can't get the fork caps off. They're the air assisted kind and I figured they unscrew just like a normal cap, but they aren't budging. Are there any tips or suggestions for removing them?

I have the same bike. Mine were very tight too. Obviously had not been out for a long time. I think I put them in a vice so I could get a good grip with my large adjustable wrench.

Make sure you loosen the top triple tree clamp bolts before you try and loosen the top bolt of the fork! They must be loose or you can't loosen the cap bolt. Keep the bottom triple tree clamp bolts tight!

+1 !!! I found that out years ago and added that note to my manual. That tip should have been included in the manual for sure! Ed

Thanks guys! I did loosen the top triple tree bolts. Looks like I'll have to put a little more elbow grease into it.

Douglas.P wrote: Thanks guys! I did loosen the top triple tree bolts. Looks like I'll have to put a little more elbow grease into it.

Make sure you use the correct size tool... you can put a lot force on to those but they can be damaged. Does it have the schraeder valve installed in it?

missionkz wrote:

Douglas.P wrote: Thanks guys! I did loosen the top triple tree bolts. Looks like I'll have to put a little more elbow grease into it.

Make sure you use the correct size tool... you can put a lot force on to those but they can be damaged. Does it have the schraeder valve installed in it?

I was trying with an adjustable wrench. Would switching to a 22mm flat wrench work better? Is there a better tool to use? I feel like it's harder since the valve is off-centre. I removed the schraeder valve first.

Forks off bike. I applied heat to the fork caps using a propane torch. and did the same for the bottom allen bolts.
I use a big crescent wrench & a spare triple tree as a clamping device.

If you plan on removing the bottom allen bolts, use a hardened 8mm allen socket or brake caliper socket. a cheap tool might not be up to the job & could ruin the allen bolts.

Still no luck with this . Not sure why it's being such a pain. These turn the same way as a regular bolt right? Left to loosen?

Counterclockwise to loosen.

Nessism wrote: Counterclockwise to loosen.

Thanks. Glad I'm at least doing that right.

You might try sliding one at a time out of the clamps and try heat to the tube ... Not the top bolt cap.