Fork cap stuck #@%*@!!

[chilli]

It's a '95 SR250 with the cap/o-clip style forks.

I have a nasty suspicion that the PO or someone has jammed the cap down too far and it's jammed on the lip inside. It was below the o-clip and doesn't move. Got one out fine (with the usual amount of swearing)

Any ideas on how to get the sucker out???

Only thing that I can think of is to dismantle from the bottom end (gonna be nice as it's full of oil) and use a rod to push it up through. Either that or see if I can buy a spare cap and drill and pull the old one.

 

[crazypj]

Yamaha? with circlip holding it in?
Push it down as far as it will go (use a hammer and a drift)
Clean out all the rust, grease it up and it should pop out with slight pressure. (just don't stand over it, incase it comes out fast)

 

[chilli]

Yamaha? with circlip holding it in?
Push it down as far as it will go (use a hammer and a drift)
Clean out all the rust, grease it up and it should pop out with slight pressure. (just don't stand over it, incase it comes out fast)

You're right on the Yam/circlip part. Thing is the cap seems to be jammed in the "down" position, the circlip is already out and the cap's just stuck in there so I'm not sure how I can get it to release. I get the feeling that the last time anyone did anything to the forks they thumped the cap in there and it jammed... Looking at the other fork there's a slight lip inside (I'm assuming to stop the cap dropping too far into the fork tube) and I'm thinking it's jammed onto that.

 

[scm]

Hi Chilli!

You've already mentioned the proper solutions:

take an airgun, remove the bottom bolt and try to
push the cap out from below with the strongest bar
that fits through the thread in the damper-rod.

If this doesn't work cut a let's say M10 thread into
the cap and pull it out with a bolt. If you use the yoke
to hold the forkleg make sure not to clamp the cap...

Good luck!
Sven

 

[chilli]

Hi Chilli!

You've already mentioned the proper solutions:

take an airgun, remove the bottom bolt and try to
push the cap out from below with the strongest bar
that fits through the thread in the damper-rod.

If this doesn't work cut a let's say M10 thread into
the cap and pull it out with a bolt. If you use the yoke
to hold the forkleg make sure not to clamp the cap...

Good luck!
Sven

Thanks,

I'm loathe to try dismantling from the bottom as there's a common problem with the allen bolt not undoing properly and needing to jam it with a rod/pole/"yamaha special tool" from above to stop it spinning inside the fork.

 

[scm]

Hi Chilli!

I know exactly what you mean, but in 9 out of 10 cases you can do it
without the special tool if you have the air gun (sorry I don't know the
proper term, I mean something like this:

If you slightly compress the forks there'll be some force that
pushes the rod down on the bottom of the fork leg (btw. re-
gardless of preload only when the fork is being compressed!)
Normally that creates enough friction to make everything come
loose.
Give it a try, it ain't much work!

Best regards
Sven

 

[chilli]

Well some success!!

Decided to try taking the bottom off and the gods must have been smiling as the allen came out like a dream. Just got to remove the internals and punch the cap out. No idea how, I'm assuming I just pull them...

Anyways, glad I decided to do this because......

First fork oil,

bit black and gunky so figured a change is good.

The problem fork....

WTF.... Gravy anyone?

 

[chilli]

OK so I have the fork separated, any idea how to remove the internals through the bottomof the fork tube?? Don't want to force anything and cause more probs!

 

[scm]

... any idea how to remove the internals through the bottomof the fork tube??

Ha, that's not provided! They intended to remove the rod to the top...
That's why I wrote: "... the thickest bar that fits through the thread..."
If it's M8 it'll be just a quarter of an inch, probably not enough for your
demands. That's why I wrote "... if it doesn't work cut a thread into the
cap..."

Best regards
Sven

 

[chilli]

Ha, that's not provided! They intended to remove the rod to the top...
That's why I wrote: "... the thickest bar that fits through the thread..."
If it's M8 it'll be just a quarter of an inch, probably not enough for your
demands. That's why I wrote "... if it doesn't work cut a thread into the
cap..."

Best regards
Sven

Don't I Just know it! When I get a chance I'll pop out and get some thin rod to slide up inside the damper rod don't have anything thin/long enough here. I don't think the cap's jammed too far, just enough to f... up my day, so as long as I can hit it from below I reckon it'll let go after some tapping.

Thanks for yr help mate.

 

[scm]

Cool down, you're close to causing some real damage...

 

[chilli]

Cool down, your close to causing some real damage...

Hehe, I'm actually pretty calm. Basically I just have to wait til the wife gets back (waiting around for a delivery) so I can pop out to get some rod, then it'll be tap, tap, tap rather than lumping it... Now I have access to the lower side of the plug I don't reckon it'll be too hard to get it to let go, a little patience and wd40 maybe...

All I wanted to do was change the bloody fork oil...

 

[scm]

All I wanted to do was ...

... are the words many funny stories start with!

 

[chilli]

Wooho! The war rages on, but this battle is mine.

A length of 6mm steel rod up through the damper rod, and a couple of firm taps later out pops the end cap! Man there's some crud inside, must been slowly letting water in over god-knows how long.

Need a new o-ring rubber for the cap as well but at least all's pretty much as it should be now. If anyone wants an arse-backwards tutorial on dismantling forks, let me know!