1990 ZZR600 fork cap removal

[Diddums]

Hello! I'm about to lose my mind over these caps. I'm trying to replace the fork seals and dust seals on my 1990 ZZR600, and I'm coming up against these caps which I don't seem to be able to remove:

https://i.imgur.com/T4rNGlZ.jpeg



Anyone got any ideas?

Cheers![/img]

[Diddums]

Screw it, despite doing everything myself on the bike, this is where I have to draw the line. I'm gonna end up injuring myself if I carry on with these forks, they're going to a mechanic on Monday who will do them for me.

[A100man]

[Raffles]

If you don't have a suitable vice available you could always re-install the fork legs back into the yokes and clamp 'em up. That way you will have both hands free to work on the fun bit.
Once you've got the top plug moving (see post above) simply depress it and apply DOWNWARD pressure on the retaining ring at either of it's ends and out it will pop.
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A good loser will always be a loser.

[stinkwheel]

Put it back in the yokes then you can hook the legs of a 2 or 3 leg puller under the top yoke and the screw will fit nicely into that dimple. You can then relieve the spring tension and fish out the circlip that holds it in place and (importantly) let the tension off slowly so the cap doesn't fly in the air then land on your tank, chipping the paint. Although best to put a rag on the tank anyway.

I've also done it using a t-bar on a socket extension, a 2-man job, one pushes down on the T-bar, the other fishes out the circlip.
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“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.