1982 kz750 front fork top plug removal..

darc helmit · 05-22-2007

so i was getting ready to change my fork oil. i let out the air and drained the oil. then .. neither top plug would come off. i tried wd40, a wrench, vice grips, tapping it, loosening the triple tree .. nothing worked. i beginning to believe i'll need to get new forks but maybe there's some trick they didn't explain in the service manual.

thanks for the help,
.d.h.

coppertales · 05-23-2007

similar to a KZ1000. I use a socket with a half inch breaker bar to break the caps loose. It will take a bit of effort, they stick. If you want an interesting experience, pull the drain screw out before bleeding off the air pressure.........used fork oil does not come out of clothes.......chris3

Forgot to add: your fork cap may be held by the upper triple tree bolt so loosen it first......chris3

herk · 05-23-2007

Remove the forks from the bike, then apply some heat with a propane torch.

Mine were stuck - wouldn't budge. After applying the heat, they came right out with a crescent wrench. It's helpful to remount them in the triple tree. I have a spare triple tree, so I do mine on a work bench with the forks sticking up a few inches out of the upper triple so that I can clamp the uppers & lowers. JMK.

05-22-2007	#1 (permalink)
darc helmit Newbie Join Date: Feb 2007 Posts: 4	1982 kz750 front fork top plug removal.. so i was getting ready to change my fork oil. i let out the air and drained the oil. then .. neither top plug would come off. i tried wd40, a wrench, vice grips, tapping it, loosening the triple tree .. nothing worked. i beginning to believe i'll need to get new forks but maybe there's some trick they didn't explain in the service manual. thanks for the help, .d.h.

05-23-2007	#2 (permalink)
coppertales Uncle Bob's Love Child BTK Expert Join Date: Mar 2007 Posts: 283	I am guessing your forks are.... similar to a KZ1000. I use a socket with a half inch breaker bar to break the caps loose. It will take a bit of effort, they stick. If you want an interesting experience, pull the drain screw out before bleeding off the air pressure.........used fork oil does not come out of clothes.......chris3 Forgot to add: your fork cap may be held by the upper triple tree bolt so loosen it first......chris3 Last edited by coppertales : 05-23-2007 at 12:01 PM. Reason: add info

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05-23-2007	#3 (permalink)
herk bustedfeet BTK Expert Join Date: Jun 2006 Posts: 1,137	Remove the forks from the bike, then apply some heat with a propane torch. Mine were stuck - wouldn't budge. After applying the heat, they came right out with a crescent wrench. It's helpful to remount them in the triple tree. I have a spare triple tree, so I do mine on a work bench with the forks sticking up a few inches out of the upper triple so that I can clamp the uppers & lowers. JMK.

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