Wanted: Fork Bolts, aka fork caps

[Disco]

Figured I'd start here.  Does anyone have a spare pair of Valkyrie or VTX1800 fork caps laying around?  How 'bout a pair of forks that are too ugly or bent up to use? 

While working to rebuild the forks on the rescue Interstate, we found that 1) judging by the color of the oil, they had been serviced recently, and 2) whoever replaced the caps must have used an impact wrench on them.  (they only require 37 or 41 foot pounds, depending on which page you look at in the service manual)  The result of the previous work was rounded hex heads and ridiculous tightness.  While removing the RH cap, the 24mm hex rounded off.  We hammered a 23mm on in its place, that worked and the fork was rebuilt, but it needs a new cap.  While attempting to remove the LH cap, it too rounded off.  We hammered the 23mm on it, but we still could not remove the cap.  My next step will be to Dremel a slot in the head and use an impact blade, but it will need a new cap, too.

Thanks!

Dave

[Houdini]

Dave, Dave, Dave, did you forget to loosen the pinch bolts?   

[Disco]

Forks were out of the trees.   

[RainMaker]

If it's already boogered up, use a pipe wrench.  It will bite into the aluminum and give you the leverage needed.

[franco6]

Dave did you try a heat gun or torch?

[godfire]

Damn! Sounds like fun.... wish I was there!!!

[Disco]

Dave did you try a heat gun or torch?

Not yet, but I've gotten up to a 24" pipe wrench.      I'll stay away from a torch as I have PB Blaster trying to soak in, but the heat gun deserves a shot.

Damn! Sounds like fun.... wish I was there!!!

We wish you were here, too!      How are things, Jim?   

[Disco]

Short version:  No success removing LH fork cap.         Valkpilot to the rescue with an extra pair of forks!   

Long version:  Before escalating, I gave the pipe / strap wrench approach one more session, this time with 2 strap wrenches, with the only tangible result being a broken strap wrench.  Next, I gave the cap an overnight dose of PB Blaster.  I didn't think it would help, but it couldn't hurt.  Next, I cut a slot in the rounded head and used the impact blade.  (I learned it's actually a steering linkage adjustment tool.)  It's not really impact duty, but it is certainly harder than the fork cap.



No good luck.

Next, I drilled two half-inch deep F bit holes, tapped them with a 5/16" - 18 tap, ran two bolts in, placed the fork in a vice wrapped in a rubber mat (really big strap wrench)and put the 24" pipe wrench on them.  I used constant and momentary pressure with the only tangible result being a bent 5/16" bolt.  Then, I broke out the heat gun. 



No good luck.

At this point, I believe the threads are galled.  Even if I were to eventually remove the cap, I'm almost certain the tube will not be useable.  Sad to know that careless reassembly has claimed another good part. 

[RainMaker]

Wonder if they used loc-tite or some other glue on them?  If you ever get the cap off, you could retap the threads but there would still be doubt.  It's a shame.