Can you buy replacement front fork caps...?

[hikermikem]

Can you buy replacement front fork caps that just have a hex on the cap, without the port for the air valve?

I don't use air any longer since I put the progressive springs in, but threading that stock cap on is a nightmare - the square-ish head is off center & doesn't fit into a socket.

Just wondering what others do to get those buggers on...

Thanks,

Mike

[trippivot]

I use a big cresent wrench and the flat of my palm.

First you need to reference where the 2 thread ends are with the spring out.. mark with a marker or just remember cap and tube position ... put spring in... put oil in... get ready.. get the cap in place -in line to catch the thread- and push - feel for the catch . do again until the bugger goes in...

jack under the bike frame if you are using the trees for support.

a vice needs to be 8~10 inches below the threads and use soft jaws.

thread is different than any other caps I have tried so I have the top nipples too..

[bwringer]

Depending on which bike you're working on (details, people, details) you can likely order caps for a later model.

For example, my '83 GS850G has lovely hex caps instead of those horrible lopsided wonky air fitting caps. Much easier. So you could look on the fiche for an '83 and order those caps for an earlier model.

The fork air fittings on an '83 are set up in a different way than earlier models.

If it's for one of your other bikes, I dunno, but you should be able to rummage through some fiches and figure it out. If the fork seal is the same part number, the tubes are the same diameter.

[bwringer]

Also, if you're stuck with those awful lopsided caps, get a 22mm deep well socket and cut a window on one side with a Dremel cutting wheel so it basically ends up "C" shaped at the business end. Put a layer of duct tape on the inside to prevent scratching, and now you've made yerself a handy fork cap re-installing tool.

22mm is the right size for the caps on a GS850, but I don't know about the other models.