[Christ’s Custom Creations]

Doing a fork rebuild and can’t quite figure out how to remove the caps as they’re threaded for the covers, I’ve talked to various mechanic friends and so far we all agree that we’ve never seen anything like them before, any advice?

 

[RoadRunner322]

Just make sure the air pressure has been released and unscrew the caps.

 

[martin-csr]

You may have to loosen the upper triple clamp bolts. And it may help to apply heat, but relieve the air pressure & drain the oil and do this with the forks off the motorcycle.

The fork caps thread into the fork tubes. The fork cover ears fit over the fork tubes. The air valve assy fits over small holes in the fork tubes and there are gaskets & o-rings to seal the air valve assy. see diagrams at Partzilla. eebbaayy photos are helpful for stuff like this >> search the part numbers or use other searches, such as ZN700 forks.

My fork caps were stuck, so I removed the forks from the motorcycle & applied heat using a propane torch. To remove them I had a spare triple to use as a clamping device. Otherwise, you may have to re-install the forks to remove the caps, but don't tighten the upper clamp bolts.
....

 

[RoadRunner322]

Yep, Martin is correct. You do have to loosen the clamps to unscrew the caps. How soon I forget. I've replaced the fork seals and removed the fork tubes all three times over 10 yrs.

 

[martin-csr]

CCC: I mentioned the air valve assy above & was referencing the air equalizer with rubber tubing between the forks that's just below the fork covers (not the air valves at the fork caps where you add air).





....