What size of wrench or socket?

[anesthesia]

To remove the fork caps on an '03 SS750?
My bike didn't come with any tools and none of my sockets or wrenchs are big enough.

Tried a crescent wrench, but am afraid of it slipping and chewing up the cap.

[RustyJake]

I'd guess 24mm. can't remember for sure, but I think that's what I used. Make sure you just loosen it with the wrench then put a cloth over the nut and take it out by hand. It's spring loaded and will fly on you.
On reinstallation, be VERY careful NOT to cross thread it.

[JetDoctor]

24 mm it is. I just checked on mine.

[anesthesia]

Thanks. I'm putting on some fork extensions and I cranked pretty hard with the crescent tonight and couldn't get it to budge.
I'm hoping that with the right fit that it will come loose.

[AirportFF]

Thanks. I'm putting on some fork extensions and I cranked pretty hard with the crescent tonight and couldn't get it to budge.
I'm hoping that with the right fit that it will come loose.

This may seem like a stupid question, is the bike off of the ground? Also when re installing the caps. Put a touch of oil on the O rings so they don't bind up and tear when you tighten the cap.

[anesthesia]

Still on the ground. I figured I'd loosen them before I lifted it for more support. Does it need to be off the ground to loosen?

[AirportFF]

On the ground, all the weight of the front suspension is pushing against those caps. I would recommend lifting it then removing them

[anesthesia]

Thanks, didn't think of that. Just figured the bike would be a little more stable sitting on the ground.

[AirportFF]

You do have a motorcycle lift, right? Get the weight off of the front end and strap it down. I had our bikes on the lift for the better part of last winter while I was building them. If you have the right lift it'll be pretty stable.

[anesthesia]

Yep, have the DIY lift that I posted in one of the other threads. I'll try that and see if I can break the caps loose.

Next, it's the Billski taillight and paint. Only problem, the weather has been so nice here in Colo. that I don't want to start taking parts off the bike when I can be riding it. I'm actually praying for some snow, just so I'll stop riding and start working on the thing.

[pegscraper]

I have a big pair of vise grips you can borrow.....

[anesthesia]

Damn! I still can't get those frickin things loose. Bought a 24mm socket and ended up stripping the socket wrench. Tried a pry bar on the wrench and the caps won't budge.

The bike is an '03 Spirit. I bought it in August and keep it garaged, but really don't know if the guy I got it from did. There's no rust and looks like it was kept out of the elements. The guy I bought it from moved out from Missouri.

I can't think of anything else short of taking it to a shop once I get everything painted and all put back together.

[RAZOR]

I Have Never Messed With Them -- But A Question For Those Of You That
Have -- Or They Reverse Threaded....
And Anathesi. Or You Sure Your Wrenching The Right Way?? Just
A Thought....like I Said I Never Messed With Them..

[RustyJake]

I Have Never Messed With Them -- But A Question For Those Of You That
Have -- Or They Reverse Threaded....
And Anathesi. Or You Sure Your Wrenching The Right Way?? Just
A Thought....like I Said I Never Messed With Them..
Nope, righty...tighty, lefty.....loosie.

Can't imaging that they'd be on so tight as to strip a socket. Are you sure you have the front tire off of the ground to relieve all pressure on the springs????

[anesthesia]

I was wondering if they were reverse threaded myself, thanks for the info.

Tire's off the ground, top part of the tree is loose.

Stopped at my local bike shop to check with them and 2 of the people that worked there as well as 2 customers agreed with you guys that it should not be this tough. Especially enough to strip a socket.

I sent Billski an email and he called me and told me to try a box wrench and tapping it with a hammer. Too cold today (2-3" of snow) to go out in my little unheated, never gets any sun garage.

Hopefully, I can take care of it tomorrow. Otherwise, with my temper, there may be some somewhat usuable 03 Spirit bits and pieces for sale soon.:laugh4:

[gozz2121]

Just be real careful when the nuts are ready to come off, I know a guy, not gonna mention any names (me), who bout lost a finger when to springs came flying out. Those spacer tubes should be considered weapons, cut clear to the bone. Anyway Good Luck. :furious3:

[RustyJake]

Do yourself a favour, throw some heat on in that shed (keep it safe though, make sure you don't light anything on fire, a little ceramic heater on in there away from anything flamable should work). Working with dis-similar metals which both have different rates of expansion due to the cold as well as a cold o-ring is only going to compound the issue.
When you say the top part of the tree is loose, are you talking about the pinch bolts? Because you shouldn't have to loosen those at all to remove the cap.

[anesthesia]

Do yourself a favour, throw some heat on in that shed (keep it safe though, make sure you don't light anything on fire, a little ceramic heater on in there away from anything flamable should work). Working with dis-similar metals which both have different rates of expansion due to the cold as well as a cold o-ring is only going to compound the issue.
When you say the top part of the tree is loose, are you talking about the pinch bolts? Because you shouldn't have to loosen those at all to remove the cap.

Yeah, I had thought of that and am going to get a heater. The garage is small, barely fits my car, so we use it for storage and the bike. It butts up to the neighbors garage and never gets any sun this time of year.

I loosened the top pinch bolts after not being able to get the caps loose, thought it might help. Hopefully, I can give it a go this afternoon, then we can move on to whatever my next problem will be.

Thanks for the tip gozz, I'll try to keep body parts clear.

[AirportFF]

Do yourself a favour, throw some heat on in that shed.

I thought you were gonna use my line of "use a big blowtorch"

[RustyJake]

I thought you were gonna use my line of "use a big blowtorch"
He's at that point where he might actually use it.

[anesthesia]

He's at that point where he might actually use it.

F that. Tried it again today tapping the wrench with a hammer and still nothing. Let's just say I went a little beyond tapping and the wrench I bought yesterday is not returnable anymore.

A friend that used to work for a Honda shop and rebuilds Harleys, Ducatis, Triumphs and whatnot is coming over tomorrow to help. If he doesn't destroy the bike, I will.

I'm getting really, really pissed. All over fork extensions.

[JetDoctor]

You must have some strange shit going on there. I loosened mine off yesterday cause I will be installing new trees and fork extentions. They came off no problem. Hopefully your buddy can help you out!

[pegscraper]

Maybe try welding a 4 foot extension bar to the cap. That should give you enough to get it off. OK, just try a cheater bar on the end of the wrench if you haven't.

[Machinehead]

I can only see three options at this point.

One: Cut off a 3in block of wood from a 2x4. Tape the jaws of a crescent wrench with electrical tape (to protect what's left) and use it to apply pressure while an assistant (armed with a hammer) taps the top of the cap with the block and hammer.

Two: Use an impact. It's more than likely you'll mar the finish using this method.


Three: Use a torch (propane ?) to heat the tube (maybe a few inches below the cap) in an attempt tp expand it for removal, but before you try this method you may want to drain the flammable fluid and leave the drain plug off. Also, the small amount of heat applied may distort the upper o-ring in which case would warrant a replacement.

GL,
MH