How do you get the fork caps back on?

[Ghostt]

Okay so I've done the fork & dust seals, got the oil in, and tried to get the caps back on with no luck whatsoever. I've even had a friend help me to push the spring down & cap, but still can't seem to get it.

Am I missing something here, I've done this on other bikes before, and never had an issue where I couldn't get the caps on.

Any tips, advice, etc???

I didn't remove the upper forks, so they are in the triple tree.

Thanks for any insight

[CrystalPistol]

I've used a 12-14" long 2x4 with a recess drilled in the center of one side, used a Forstner bit myself, about 1" or 1-1/2" diameter, just maybe 1/2" deep. Then a 1/2" drive "speed wrench" looks like a crank for a model T, a suitable socket, bike on center stand of course, blocks under motor to keep all weight off front forks, stand on foot pegs, board across my chest, lean forwards, swivel of speed wrench in recess, my weight helps to press down as I use hands to slowly engage cap into threads by turning crank.

On my trike it easier because the caps have air fittings I can remove and drop a 2 or 3" long 1/4" bolt down through to keep cap on spring, but on the 1200, no hole OEM but I have drilled & tapped them for a plug so I can use the bolt drop guide deal.

[ct1500]

Make sure the front wheel is off the ground. With springs removed make a paint mark on cap and tube just prior to where the threads start to engage, this is where you want cap to be when compressing spring. With the appropriate socket, extension length and ratchet stand on passenger floorboards leaning forward bringing your weight down on ratchet under your chest, tighten away.

[julimike54]

If your weight and friend(s) can't make it work, I'd go searching for the fork cap tool. I think Motion Pro makes a tool for this operation, might check with them.

[ct1500]

Option 2 off the bike (easiest).
Have assistant hold extended fork tube grasping both upper and lower where the dust seal is with slider resting on ground. The chunkier guy will bear straight down on cap, aligning marks while assistant turns upper tube without it sliding down, engaging threads of cap. Most wives can handle that part

[WingAdmin]

I have the Honda fork tool, which makes quick and easy (and safe) work of this.



You can see me using it here starting at step 57: viewtopic.php?f=14&t=16118

It can be bought here: https://cyclemax.com/inc/sdetail/fork_s ... ool/269193

[Uncle Werner]

Hi saw this and decided to build my own. Use it to change the seals.I decided there was an easier way when changing out the oil. I drilled and tapped the Bolt (cap)fine thread. For the bolt I use a small rubber o ring and light coating of blue silicone No leakage considering its only 6 psi for the shocks. Drill a chamfer, enough to seat the oring. I can change the oil yearly whether I need to or not. I make it a habit of changing all my oils. Its so cheap and best for your parts.

[Ghostt]

Update:

First of thxs to all for your advice, second it's back together again.

I used a mix of the advice, the combination helped and made it a lot easier.

Once again thx u all.