Cross threaded fork cap

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03 Nov 2017 14:14 #774170 by lgyee4
Cross threaded fork cap was created by lgyee4
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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03 Nov 2017 15:00 #774172 by Scirocco
Replied by Scirocco on topic Cross threaded fork cap
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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03 Nov 2017 15:02 #774173 by Patton
Replied by Patton on topic Cross threaded fork cap
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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03 Nov 2017 15:26 #774176 by Scirocco
Replied by Scirocco on topic Cross threaded fork cap
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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03 Nov 2017 16:50 #774182 by lgyee4
Replied by lgyee4 on topic Cross threaded fork cap
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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03 Nov 2017 17:34 - 03 Nov 2017 17:41 #774189 by Scirocco
Replied by Scirocco on topic Cross threaded fork cap
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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03 Nov 2017 18:17 #774191 by lgyee4
Replied by lgyee4 on topic Cross threaded fork cap
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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03 Nov 2017 19:29 #774197 by 650ed
Replied by 650ed on topic Cross threaded fork cap
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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03 Nov 2017 19:31 #774198 by SWest
Replied by SWest on topic Cross threaded fork cap
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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04 Nov 2017 04:40 #774200 by Scirocco
Replied by Scirocco on topic Cross threaded fork cap
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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04 Nov 2017 08:08 #774209 by lgyee4
Replied by lgyee4 on topic Cross threaded fork cap
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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04 Nov 2017 11:38 #774221 by lgyee4
Replied by lgyee4 on topic Cross threaded fork cap
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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