KZ440 Fork - Cant Remove End Cover

  Hi Folks!

I am trying to rebuild my fork. So far everything went well and I removed the surclip but I can’t remove this metal cover. As far as I understood it should pop right off once the surclip is removed but mine seems to be stuck.
Any Ideas how to remove this?
Tried rust solvent + pneumatic needler.


Greetings Lukas

Just Rust/Muck holding the o-ring in place. Do You have a drill and taps? If so, just drill down the center of it, easy because it's already a dimple. Use a twist bit that will be accommodating for the tap. Something as large as that i would go 8mmx1.25pitch. Stud the tapped hole. With a selection of spacers over the top (strong/thick enough?. Nut the stud and wrench it out. Ya might remove the damper allen at the bottom before this task is implemented though. An impact and M6 allen socket is probably the size or close. Then after removal, just grub screw it to fill the hole you've made.  

Build up a puddle of PB Blaster, or similar, on top of the cap, and wait.  Use a screwdriver or similar to push down on the cap, then allow it to spring upward quickly, under fork spring force.  Once the corrosion is broken, the top cap will fly off.  Be sure it doesn't smack you in the nose.