KZ440 fork cap removal

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wrote:

I'm wondering if anyone has replaced the circlip with a snap ring? 

I don't think the snap ring would be secure.
I believe the groove in the fork tube is round to fit the round clip, and also the cap has a bevel on the top edge to capture the clip.  That's why you need to push the cap down to reveal the clip.  At least that's how it was on the gpz550 I worked that had a similar setup.  

The snap ring certainly wouldn't be captured by the cap, and I suspect the square edge of the snap ring would not hold on to the groove in the fork tube very well.

Noted...I'll leave this alone.  My son is a mechanical engineer but I'm not so I'll defer to Kawasaki's finest.

or remove the circlip the way F64 says. 

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or remove the circlip the way F64 says. 

I completely agree and F64's method should work fine, it's just as I get older I like things to be controlled and less of a fight hence the suggestion of the puller since it's not a lot of money

wrote:

wrote:

or remove the circlip the way F64 says. 

I completely agree and F64's method should work fine, it's just as I get older I like things to be controlled and less of a fight hence the suggestion of the puller since it's not a lot of money

I like your method, dude!  It lets you separate pushing down the cap & removing the circlip instead of trying to do both at the same time....thought it was very clever

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Could you use a "two legged " puller hooked under the tree to hold the plug down while you concentrate on the clip (would also allow you to release the spring in a controlled way) could also be used to compress the spring for re-assembly ? Something like this

 

Solid idea!

Well I finally got those jokers removed with the help of my wife...I'm giving serious thought to taking those tubes to a machine shop & having threads cut.  Man was that aggravating!