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Sportster Motorcycle Suspension, Frame, Forks, Handlebars, Fuel Tank, Oil Tank, Fenders Discuss Sportster Motorcycle Suspension, Frame, Forks, Handlebars, Fuel Tank, Oil Tank, Fenders problems, advice, and/or how tos.

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fork cap, fork seal, forks

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  #1  
Old 16th February 2020
T_worth T_worth is offline
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Default Seized 1200SPORT Fork Cap

I’m attempting to change my fork oil seal and oil on my 97 1200S and can’t loosen the fork cap on one of the forks. I’ve put PB Blaster and heat on the threads of the cap but it won’t budge. The Sports have a 12point cap with fork adjuster. Im hoping Im able to loosen the fork cap without having to loosen or adjust the fork adjuster. Hopefully someone can tell me.

I don’t have a fork spring compressor that the manual mentions for the removal. But think I can get away with just leaving it on the fork cap.

Any advise would be helpful.
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  #2  
Old 16th February 2020
decman decman is offline
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I've never seen a 12 point cap on any 1200S or a FXDX.
Try putting the tube back in the triple tree for leverage.
I always loosen them up in the tree before I remove the forks.
MAke sure you have the right size wrench too.
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  #3  
Old 16th February 2020
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Quote:
Originally Posted by decman View Post
I've never seen a 12 point cap on any 1200S or a FXDX.
Try putting the tube back in the triple tree for leverage.
I always loosen them up in the tree before I remove the forks.
MAke sure you have the right size wrench too.

I guess it’s a 6point, I’m counting every flat spot (12point). Anyways. My forks are still in the triple trees for leverage. The only thing I have large enough is an adjustable wrench. It loosened the right fork just fine. The left is giving me trouble.
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  #4  
Old 16th February 2020
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You won't get that cap off using an adjustable without deforming the cap in the process. I had to replace mine... If you want to do this yourself you'll have to buy the right size socket.
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  #5  
Old 16th February 2020
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Quote:
Originally Posted by neilp View Post
You won't get that cap off using an adjustable without deforming the cap in the process. I had to replace mine... If you want to do this yourself you'll have to buy the right size socket.
I’m not sure an extended socket will fit over the adjuster though.
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Old 16th February 2020
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Rereading the manual again. I've never disassembled the forks before, so I'm not sure what to expect. The instructions for "REMOVAL" of forks state to loosen the fork cap while in the triple trees.

In the "DISASSEMBLE" section, the first step states to loosen the allen bolt at the bottom of the slider. Then continue removing the fork cap.

is the fork adjuster, fork cap, damper rod, and allen bolt all part of one assembly? If I loosen the allen bolt at the bottom of the slider, will that allow me to unscrew the cap?
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Old 16th February 2020
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Bring the fork's tube up about two inches pass the top tree, tighten the pinch bolts and the cap will be easier to remove without the clamping effect.
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Old 17th February 2020
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Quote:
Originally Posted by rejeanprimeau View Post
bring the fork's tube up about two inches pass the top tree, tighten the pinch bolts and the cap will be easier to remove without the clamping effect.
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Old 17th February 2020
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Alright alright. I took a step back, had a beer, and then went to autozone and got the correct 35mm deep socket. Worked like a charm. Thanks for bearing with me guys.
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Just two points for future readers...

The top 3T clamp usually clamps the threads - So you have to loosen the top 3T but leave the bottom clamped tight...

Some sockets have a rounded mouth to make getting it on the bolt easier - You may have to lathe, grind or file that face down 1/8" to get a clean, tight fit onto the caps...

But, as already mentioned, having the right size socket is important...

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