Fork plug seized and unremovable
 

So I'm upgrading to black lower legs and I pulled the front end apart today. Pulled the cap off the left fork, slid the leg down in the trees, like always, and pulled the plug. No problems. Rebuilt the leg and put on the new black slider and reinstalled all in about half a beer and 45 minutes.

Here's where it all goes wrong

Obvious next step, repeat on the right side, right? Not a snowball's chance in hell! I got that plug to turn about 1 thread, with some major force I might add, and not a millimeter more. I tried penetrating oil, heat, even pulling it off and putting it into a homemade vice clamp that has worked before. I can force it back on, but it seems to hang at the same place trying to remove it. thing is, these legs have never been off the bike (2013 FLHTCU). Last resort will be take it in and let the shop try.

Now, at the risk of sounding like a dick, I know how to use trees to remove the plug, I know external vise clamps don't always hold, I've seen removal videos for forks. I've removed, disassembled, rebuilt, and reinstalled forks many times, but thank you.

Anyone experienced this phenomenon and come to a resolution?
Thank!

Are you talking about the fork cap? If so, I would try an air gun. If it is that tight you are probably going to see some damaged threads when it comes apart.

Yeh not sure what part you are trying to remove, pics worth 1000 words. But based on the general description, I might take her to the shop before things go sideways.

https://cimg5.ibsrv.net/gimg/www.hdf...b17c9b23d.jpeg
Sorry, thought I explained things in the first paragraph.
Cap is on top, holds the leg to the tree. I’m talking about the plug, which holds the spring under compression in the leg.
and to late, they were already sideways when I started on this nasty wench.

I agree Dan, IF these ever come apart, they will probably never go back together again. Considering ordering new tube and plug and just cutting these to get the guts out. REALY last resort. LOL

Ok now we know what you are trying to do.

I do what it appears you are doing, lower them so the are still pinched by the lower tree. Have someone else there to hold the bike, big wrench with a pipe if you need it. If the threads are already messed up by the last guy, you probably need a new cap and tube anyway. Hate to say it, but unless someone else has a better idea, I would gorilla that thing off. At least you can save the internal parts. I would imagine the tube and cap are not big $$$ if they need replacing. Seriously, good luck.

Thanks for the input, but yeah, been there, done that, got the bloody knuckles to prove it. I think I’m just FUBAR on these and rather than pay the shop $50+++ I should just order new. Surdyke has the plug, and tube for $104 shipped.

in about half a beer and 45 minutes
 

There's your problem. You need more beer.

Hell with beer, after that cluster F**k last night I switched to scotch!

Maybe you're not doing the same thing I've done a bunch of times, but I've never had to remove that cap to just change the fork legs. 13 and below anyway.