Stuck fork cap

[kendunn]

I have a 43mm WP fork that the top cap is stuck. I have loosened the top triple clamps and put an impact on there but no luck. Any ideas? Anyone have a spare in case I have to cut?

 

[pscook]

If you are this far into it, try a little heat around the threads. Use a hair dryer or heat gun to warm it, then tap around it with a hammer. Not too hard, maybe on the top so you don't dent the tube. Heat and shock usually work to start the process.

 

[kendunn]

Tried a heat gun, nothing. Took a chisel and beat the crap out of it and nothing. Ended up putting that sucker in a chop saw and shaving the cap right at the top of the tube. Came right off. Put in new seals, put her back and screwed the cap down hand tight. Was even able to get the bleed screw back in! It actually looks trick and other than I hope my rebound was set right seems to work until I can find another! Anyone have another?

 

[Jakobi]

I would have continued with the cycle. Heat and impact. Heat and impact. Warm it up. Tap the top to shock the threads. A few braps with the impact gun. Repeat. Maybe flip the fork upside down to get oil working into the threads from inside too.

All said and done now though.

 

[kendunn]

Excellent idea from a suspension guy over on KTMtalk.

"Sounds like it's too late for that cap, but there is a better way. We clamp the fork tube between v-blocks in a bench vise and tighten a spare top triple clamp around the cap OD, so it clamps only the cap and not the tube. Then hit the other end of the triple clamp with a rubber mallet to loosen the cap. We have been able to loosen caps this way that would not come off any other way, plus it doesn't damage the cap."