Improvised Front Fork Spring Cap Installer

[3Phase]

Yeah, it was a nightmare installing the front fork spring caps without crossthreading them.

I looked around the garage and found a plastic sprinkler that fit over the fork spring cap. It allowed me to push down on the cap and tighten it without it a pair of extra hands with 360 wrists.


Improvised Fork Spring Cap Removal Tool












Regards,

Scott

[thewiz]

Good one, 3phase

I'm headed for that job myself pretty quick ... thx for that tip

[Ken Talbot]

Part of the trick on this procedure is to slowly turn the cap CCW a few turns first. Pay attention, and listen and feel for when the cap drops ever so slightly as you go past the end of where the threaded portions line up. Then carefully start turning CW, with just a bit of pressure on the cap, and you should feel the threads start to engage.

[3Phase]

The beginning threads of my fork tubes and caps had been torn and cross-threaded. Trying to thread these puppies by feel was not working so I stopped doing that and found something to let me eyeball the threads.

Cleaning up the threads and ensuring they threaded, seated and sealed cleanly without the springs and o-rings was no problem. There just isn't enough meat left on the first couple of threads and they really, really, I mean really, wanted to cross-thread and tear all over again.

Someone put in cheap fork seals (that still leaked) and left out the washers that go between the seals and the retainer clips so the botched the fork cap installation was no real surprise. I bought the Yamaha seals with the double edge on the lower lip but I have not been able to find the washers.


Regards,

Scott

[John]

I cut a deep groove in the end of a 2x2x12 piece of wood, and that worked wonderfully. You could easily use both hands to get the cap level, give it a few turns in the reverse direction, 'feeling' when the leads threads pass over each other, and then just push down and tighten. Very simple, I wish I had thought of it years ago, instead of tearing my palms up.

[jjwaller]

Sorry, But why not just use a socket
and ratchet with possibly a short extension? Much better feel for cross threading, and definite control of the nut.

[John]

A socket? On a Special air fork cap? I don't think a socket would sit over the air valves very well.

[3Phase]

I was headed for the scrapwood pile to make a holder when I spotted the sprinkler and said,"Hmm, I wonder...."

I got the new windshield installed and all the silly stuff fixed so I'm headed out for a ride to Aridzona today.

I know she'll run great!

Regards,

Scott (You hear me baby, you're gonna run great, right?"

[Toolmaker Tim]

Even a deep well socket?

[DeanR]

Take a Sharpie and while Slowly loosening the cap, mark the point at which it releases. This will get you real close to the point of engagement when you put it back on.

[jjwaller]

Sorry, didn't realize it was air caps and they were so different from normal ones.
Figured they just drilled and tapped the normal hex caps to install schrader valves.
Learn something every day!