How to put caps back on while forks are still on the bike.? - Steve Saunders Goldwing Forums

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post #1 of 15 (permalink) Old 06-27-2017, 05:54 PM Thread Starter
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How to put caps back on while forks are still on the bike.?

Boys, I'm really up a creek here. Just put progressives on a 1999 GL1500 Goldwing. I've tried about everything I can think of to get the caps back on but no luck so far. There has just got to be a fairly simple way to get them on and I'm ready to listen to anything.

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Jerrno
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post #2 of 15 (permalink) Old 06-27-2017, 06:51 PM
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At least you know you're up a creek. I just looked at my 96, and unfortunately, I'd say it's time to pull the forks off. No fork that I ever pulled off and down, ever had anything but that easily strippable fine thread on the caps. How much grief do you want to put yourself through, if you strip the threads? Or, have that spring loaded cap come flying at you if you didn't get more than a half turn on the cap? I've done the 1200's several times, and the 1800's, both were not easy. I have a pedestal vise, in goes the fork, a box wrench with the cap, and I end up leaning down on it while walking around the vise. Next time I do it, I'm going to build a tool to push the spring down, and hold the cap in place while I calmly screw it in.

Your choice.
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post #3 of 15 (permalink) Old 06-27-2017, 06:52 PM
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Jack up the bike from under the motor so the wheel is off the ground. Then you can put all your weight on the ratchet/socket while standing on the pegs. It's a good idea to mark on the tube and nut where the threads start.

Also make sure the upper clamp is loose.

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post #4 of 15 (permalink) Old 06-27-2017, 06:57 PM
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you have the front end lifted and supported- so the forks are fully extended?

A good socket on a long extension, a folded-up rag over the end of ratchet (to protect your chest) and lean into it

Mark where the thread starts on the tube and the cap-- align those before attempting to start thread

Note with Prog springs you reduce the amount of fork oil by 2 ounces in each fork.
Should leave you with ~10-11 oz fork oil

If you added full OE spec thats why you cant get the caps on- The Universe looking out for you!!
Too much fluid foams, making it worthless at its job
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post #5 of 15 (permalink) Old 06-27-2017, 07:32 PM
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Quote:
Originally Posted by purplerider View Post
At least you know you're up a creek. I just looked at my 96, and unfortunately, I'd say it's time to pull the forks off. No fork that I ever pulled off and down, ever had anything but that easily strippable fine thread on the caps. How much grief do you want to put yourself through, if you strip the threads? Or, have that spring loaded cap come flying at you if you didn't get more than a half turn on the cap? I've done the 1200's several times, and the 1800's, both were not easy.
I can put the caps on 1800 forks with my bare hands and I ain't near as strong as I once was. 12 & 1500s are not easy I agree.

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post #6 of 15 (permalink) Old 06-28-2017, 10:04 AM Thread Starter
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Is It really nessessery to have a washer under the cap?

Jerrno
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post #7 of 15 (permalink) Old 06-28-2017, 10:14 AM
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Is It really nessessery to have a washer under the cap?
If you're talking about # 64, then yes. Put some petroleum jelly or thick grease on it so it sticks to the cap.

And the spacers Progressive provides are needed too.

Have you got the wheel off the ground?

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post #8 of 15 (permalink) Old 06-28-2017, 02:53 PM
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I use a speed handle and an extension. It makes it a lot easier than using a ratchet handle.
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post #9 of 15 (permalink) Old 06-28-2017, 08:22 PM
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I use a speed handle and an extension. It makes it a lot easier than using a ratchet handle.


That's a great idea!

I picked up a bar clamp for when the forks are off the bike to compress the cap/spring and use a wrench under the foot on the cap. A ratcheting box wrench helps. Or a bushing to give room for the wrench. I've also used the ratchet under the bar clamp.

I've heard of people using ratchet straps in place of the bar clamp with the ratchet pinned under as well.
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post #10 of 15 (permalink) Old 06-29-2017, 04:47 AM
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When off the bike I have an assistant hold the fork tube extended and straight up while resting on the ground. I bear down compressing the spring and when the cap touches tube assistant turns the tube engaging threads.

J.D.

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