GPZ 550 fork caps

I pulled apart my forks to replace the seals and, now that I'm down to the last reassembly, I can't get the fork caps to compress.

The springs are in correctly, the forks are fully extended, the spacer washer is in place. I can easily push the spring 4-5 inches down inside the tube.

But, the fork caps only go in to where the tops of the caps are about 2-3 mm inside the fork and then they seem to bottom.I've got 10mm or so to go before the groove for the spring clip becomes visible.

What is it hanging up on? I've turned it, hammered it, pressed it and no go.

G. this may be worthless, but a vet's approch to installing /removing circlip located fork caps is simply squeezing fork tube. at a guess, you're using bike to hold tubes. if so, simply loosen upper clamp bolts. if I'm right releasing tension will allow cap to travel. metering tension will allow penetrtion and hold to allow fitting retaining ring. luck G

Well,tube compression is not an issue

I've got the tube set in my vise about 1 foot down from the top.

I've looked at it some more and it looks like the cap won't fit into the bore that's below the clip groove.

I pulled the O ring to confirm that it is not the problem

Any other ideas?

if it came out of those forks it will go back in i always put the tubes back in the trees and only tighten the bottom bolts you might some help for this next part, i use a 1/2" bereaker bar and push down as hard as i can they will go you will get more leverage if the tube is in the trees on the bike . when you get the cap pushed it to place get your helper to put in the circlip. and make sure it is seated or it will blow out in to your face at the wrong time. make sure the forks are extended all the way out before you attempt this.

timebomb33 wrote:

if it came out of those forks it will go back in i

No offense, but if it would go right back in, I wouldn't be posting as to why it won't.

Force is not the issue.

I've done this countless times on that bike and it should be easy. Forgive me if this sounds dumb, but are you sure the clip is not already in the groove?

Is it the same problem on both forks, or did you only do one?

There's no chance the cap is upside down is there? Probably not unless you took apart the air valve and put it on the wrong end. Sory, I know these suggestions are unlikely, but have to cover everything.

Thanks,

But no

and no

Both forks have the problem - I've tried switching the caps on the tubes - no luck

It does seem awfully basic, that's why I'm stumped!

Have you tried pulling the springs back out and trying to fit them in?

Yep,they still just sit there

I posted in hopes this was a more common problem, even tho I've never had it happen in 40 years of wrenching on my bikes.

I guess I'll break out the Dremel and put a little chamfer around the base of the cap to see if it will slip into place

Damn that is wierd. I hate to see ya dremel it and then realize what the problem is.

loudhvx wrote:

Damn that is wierd. I hate to see ya dremel it and then realize what the problem is.

Me too.

That's why I'm taking my time.

What with hail and 46 degrees out, I'm in no hurry. I need the garage space to work on my GS, tho.