Cross threaded fork cap

lgyee4
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Cross threaded fork cap

03 Nov 2017 14:14

The PO of my KZ1000ST has been leaving surprises on the bike for me to fix as I start restoring this to running shape. The right fork cap came off easily as usual. However, the left one didn't budge when I went to remove it. It took my impact driver to finally spin it out.
I'm going to remove the bottom three rows of threads and file in threads to see if it starts.

This is a PITA..

2 stroke rider
TZ 250, TZR 250, RD 400, RZ 350, RZ 500, WR 200, KDX 200, Vespa ET2
And one 4 stroke: 1979 KZ1000ST

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Scirocco
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Re: Cross threaded fork cap

03 Nov 2017 15:00

#774172

There is threat re-cutting tool up to 16 – 38 mm / 5⁄8″ – 1.1⁄2″
No need to remove the damaged rows. A good machine shop should do it easily in less a minute.

Michael

My 1975 Z 1 B 900 Project

www.kzrider.com/forum/11-projects/605133...ears-deep-sleep-mode

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Patton
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Re: Cross threaded fork cap

03 Nov 2017 15:02

#774173

The female threads inside the fork tube are hopefully still okay.

Would consider getting a new cap.

Good Fortune!

1973 Z1
KZ900 LTD

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Scirocco
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Re: Cross threaded fork cap

03 Nov 2017 15:26

#774176

If a machine shop can refresh the OD, he can do the ID threath

My 1975 Z 1 B 900 Project

www.kzrider.com/forum/11-projects/605133...ears-deep-sleep-mode

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lgyee4
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Re: Cross threaded fork cap

03 Nov 2017 16:50

#774182

The cap has lost material in the bottom of the threaded area. I'm trying to dress it with a thread file now. The tube is stainless and seems to be in good shape. That said, the material that was lost from the cap has become imbedded in the tubes thread and it's tough to get out without damaging the existing threads.

2 stroke rider
TZ 250, TZR 250, RD 400, RZ 350, RZ 500, WR 200, KDX 200, Vespa ET2
And one 4 stroke: 1979 KZ1000ST

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Scirocco
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Re: Cross threaded fork cap

03 Nov 2017 17:34 - 03 Nov 2017 17:41

#774189

if you lost some rows of the threat the remaining threat will do the job as before the damage..
Nothing to worry about it.
.

My 1975 Z 1 B 900 Project

www.kzrider.com/forum/11-projects/605133...ears-deep-sleep-mode

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Last edit: 03 Nov 2017 17:41 by Scirocco.

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lgyee4
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Re: Cross threaded fork cap

03 Nov 2017 18:17

#774191

That's exactly the kind of file I'm using on the cap. The tube is where I'm having a tougher time. My goal is to be able to dry fit it before I assemble the forks. The material that's left in the tube is stuck in the threads and keeping the cap from spinning in.
Is there a file or something that will help clean out the threads?

2 stroke rider
TZ 250, TZR 250, RD 400, RZ 350, RZ 500, WR 200, KDX 200, Vespa ET2
And one 4 stroke: 1979 KZ1000ST

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650ed
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Re: Cross threaded fork cap

03 Nov 2017 19:29

#774197

If you cannot pick out the old thread debris using a dental pick you may want to use a thread chaser (not tap) to clean the threads. Ed

1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)

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SWest
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Re: Cross threaded fork cap

03 Nov 2017 19:31

#774198

I'd use a small brass brush to clean them out then screw it in and out without the springs little by little, cleaning in between. Should clean up nicely.
Steve

Z1b1000 1975 Z1b
kzrider.com/forum/11-projects/598262-kz-...-will-it-live#672882
kzrider.com/forum/2-engine/597654-poser?start=240#704229

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Scirocco
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Re: Cross threaded fork cap

04 Nov 2017 04:40

#774200

Have you try this to clean the inner threat

My 1975 Z 1 B 900 Project

www.kzrider.com/forum/11-projects/605133...ears-deep-sleep-mode

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lgyee4
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Re: Cross threaded fork cap

04 Nov 2017 08:08

#774209

This is what I'm doing this morning! I'm hoping to clean it up so I can start the wrestling match getting the caps back on without breaking something else.

2 stroke rider
TZ 250, TZR 250, RD 400, RZ 350, RZ 500, WR 200, KDX 200, Vespa ET2
And one 4 stroke: 1979 KZ1000ST

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lgyee4
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Re: Cross threaded fork cap

04 Nov 2017 11:38

#774221

Crap.. can't find the internal thread files anywhere.

2 stroke rider
TZ 250, TZR 250, RD 400, RZ 350, RZ 500, WR 200, KDX 200, Vespa ET2
And one 4 stroke: 1979 KZ1000ST

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