I am breaking my front end down on my 2004 EG. Forks are off of the bike and the right side fork is completely disassembled. However I am having some difficulty get the fork cap off of the left side fork. So my question is this...Has anybody had difficulty getting a fork cap off of one or both forks? And on that note, how did you tackle the job? My next step is going to be to remount the fork in the lower tree and see if that will give me some leverage to break the fork cap loose. If anybody has any advice I would appreciate it. On a side note, I did spray the cap with some WD40 in hopes to help loosen the bolt. I know WD40 isn't the best for this, but its what I had last night. Please, share your thoughts.

 

I assume the problem is that the fork tube spins when you're trying to turn the cap... Did you try putting the fork back in the triple tree to hold it? Another option, if you have a socket large enough and an impact wrench.... have someone hold the tube while you use the impact wrench on it. The impact action will usually break something like that loose easier... but be ready for the spring to push the cap off... don't let it go flying across the room.

Ride Safely!
John.

 

 

I always loosen them while still in the lower tree.
Put it back in the lower tree, tighten the lower tree bolt, break the cap loose, and remove from tree.

 

Put the wrench on it hit with a dead blow I know tong and Hammer but that's how I did it without anything holding the fork.

 

I'm going to try to remount the tube in the lower tree tonight to get the top loose. Unfortunately the head of the fork cap is not a traditional bolt or even hex. It just has 2 flat sides and you use a regular combo wrench or big adjustable. I have done this before on my Dyna with no troubles. But the touring bikes seem to have a slightly different setup. Thanks for the suggestions so far!

 

I have a clamp that holds the fork tube in my vise. I then used a socket similar to this one to remove the cap with an impact wrench. https://www.ebay.com/itm/Fork-Tube-P...8AAOSwridaRmgb

 

That's well and good, but not necessary.
During disassembly, slide to tube out of the upper tree, retighten lower tree pinch bolt, loosen fork cap with large crescent wrench, remove fork.
You don't need a vice, a special clamp, a special socket, or an impact.
But, those things do work, if you got em.

 

I appreciate all the input. Ill let you know how it turns out!