Removing the front fork top plug

  • TeK9iNe
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21 Jul 2009 19:55 #308550 by TeK9iNe
Replied by TeK9iNe on topic Removing the front fork top plug
Proper wrench with hollow jack bar slipped over the end. Lots of torque with little effort.

B)
Motorcycle Shop Owner/Operator

79 Kawie Z1000 LTD
81 Kawie Z1000 CSR
83 Honda VT750C A
85 Kawie GPZ900 A2
86 Zukie GS1150 EG
93 Yamie XV1100 E
Lucky to have rolled many old bikes through my doors ;)

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21 Jul 2009 20:17 #308556 by JMKZHI
Replied by JMKZHI on topic Removing the front fork top plug
Apply heat to the bottom allen bolt while you're at it.
FYI: the heat had no effect on my fork cap o-rings. I replaced the air valve o-rings but reused the big ones. HarborFreight & other places sell a metric nitrile o-ring kit w the needed sizes.

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22 Jul 2009 07:28 #308634 by chrispysaki
Replied by chrispysaki on topic Removing the front fork top plug
Thanks everyone. Sounds like I just need a better wrench and more torque. I'll let you know how it goes.

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22 Jul 2009 07:38 #308635 by JMKZHI
Replied by JMKZHI on topic Removing the front fork top plug
And some heat.
There's a good chance the caps have never been removed.

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22 Jul 2009 12:39 #308692 by chrispysaki
Replied by chrispysaki on topic Removing the front fork top plug
JMKZHI, why should I apply heat to the bottom allen bolt? I don't think I'm supposed to remove that, am I?

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22 Jul 2009 17:50 #308726 by JMKZHI
Replied by JMKZHI on topic Removing the front fork top plug
I was assuming you were going to do the complete disassembly.

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24 Jul 2009 20:37 #309155 by chrispysaki
Replied by chrispysaki on topic Removing the front fork top plug
Got it! All it needed was some heat and a pipe on the end of the wrench for more torque. I really thought I was going to break something wrenching on it that hard. Thanks again for the help everyone.

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