Can't Remove Fork Tube Plugs
Ultimate HDF Member
Joined: Oct 2011
Posts: 5,691
Likes: 1,651
From: Olean, NY
I just pulled the fork legs out (since they have to come out anyway, laid them on the work bench with the cap end hanging over the edge, had a buddy with leather gloves on hold the fork tube, I used a breaker bar and just whacked it with my plastic dead blow hammer. Popped them both loose with ease. Then we had a beer.
HDF Community Team
Joined: Nov 2012
Posts: 6,191
Likes: 2,423
From: USA
In that case, what did you clamp with the vice when you were trying to remove it that way? If you'd damaged the chrome tube that the lower leg slides over, you're going to need to replace the tube. The slightest nick from the vice jaws will tear the seals. The slightest squishing of the tube will damage or bind in the lower leg slider bushing.
Supporter
Joined: Jan 2007
Posts: 15,788
Likes: 5,629
From: along the shore of Mishigami
Have you tried loosening the upper tree just enough to take the compression off the tube, then try to loosen the cap. That trick worked on my Low Rider, leave the lowers tight.
Thread Starter
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Road Warrior
Joined: Jul 2012
Posts: 1,566
Likes: 55
From: Londonderry, NH
Thank you all for the suggestions.
I got back to the problem today and torqued the fork pinch bolts til I thought they might snap using a breaker bar and extension. From all the replies, it appeared this worked for most people...so I kept torqueing them down til they wouldn't rotate.
That held the tubes in place and I was able to remove the left side cap without too much difficulty,
The right side proved more difficult. I did manage to get it off, but had to use a 1/2" ratchet with an long extension til I was close to the last thread. The spring forced it out at that point...luckily no damage. Its draining now. Tomorrow or later tonight I'll inspect the two parts to see if I have a damaged or off-center thread, or it the tube has an issue (out of round?).
After all the work it took to get them apart, I guess this is as good a time as any to order the chrome lowers I've been considering. Mine are a showing signs of road wear (at about 30K miles), and I don't want to have to do this again any time soon.
I got back to the problem today and torqued the fork pinch bolts til I thought they might snap using a breaker bar and extension. From all the replies, it appeared this worked for most people...so I kept torqueing them down til they wouldn't rotate.
That held the tubes in place and I was able to remove the left side cap without too much difficulty,
The right side proved more difficult. I did manage to get it off, but had to use a 1/2" ratchet with an long extension til I was close to the last thread. The spring forced it out at that point...luckily no damage. Its draining now. Tomorrow or later tonight I'll inspect the two parts to see if I have a damaged or off-center thread, or it the tube has an issue (out of round?).
After all the work it took to get them apart, I guess this is as good a time as any to order the chrome lowers I've been considering. Mine are a showing signs of road wear (at about 30K miles), and I don't want to have to do this again any time soon.
Seasoned HDF Member
Joined: Aug 2011
Posts: 11,814
Likes: 5,120
From: SW Ohio
I would replace those pinch bolts.
Road Warrior
Joined: Oct 2007
Posts: 1,824
Likes: 59
From: SW Burbs of Chicago
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