First post on the forum.

I am in the process of replacing my fork seals on my CBR600F. The left fork is giving me a hard time. I was very careful but still rounded of the left cap (right came off without any issues). I have tried everything I can think of. Thinks I tried:

• 24mm Socket - Rounded off thread
• Large Vise Grips - Damaged further
• #3 Screw Extractor - Screw Extractor Snapped
• Irwin Screw Extractors - Current Step

Possible Next Step. Drill two holes spaced apart and make mating tool to match.

Currently I am using an Irwin Screw Extractor with the fork moved up in tree as I was unable to hold it well in my vise. I have a couple foot bar for leverage but can't seem to break it loose. I am afraid to apply much more torque and have the extractor slip in the aluminum cap.

Anybody have some advice on how to break it free?


Thanks!

 

Oww! I would hose it with break-free, wait 20 minutes, hose it again.
Then, try to turn it. If it still won't turn, possibly some judicious heat applied.

The part is toast, so no preserving it's integrity. Instead of a screw extractor,
I would try a pipe-wrench in the 1/8 shoulder of the cap. More bearing surface,
as well as leverage.

Be careful with your vice on the fork-tube, itself. You do not want to mar it up.

Then comes the hunt for a replacement cap and the pre-load internals.

Good luck, Ern

 

That's bad luck mate.

Since the cap is done for, you could try maybe cutting/making a small slot in the edge of the cap, then use an old screw driver and a hammer to hit the cap around until it's loose (away from you and anticlockwise of course), and then use the vice grips to unscrew it the rest of the way.

 

+1 to the pipe wrench. Be careful not to damage the tube!

Maybe try extending the forks some to take some spring tension off.

 

So, I heated it up pretty hot and let it cool to see if I could get the threads to loosen. I then got a bigger breaker bar (3-4 feet) and gave it all I had. It broke free and came off. Screw extractor worked really well!

However, I now have a new problem. I didn't realize the collar was abs or some type of plastic and isn't looking so good. Need to find a replacement.

Two questions:

• Are the originals plastic?
• Any suggestions on where to get replacements? (I check BikeBandit and Powersportsplus with no luck. Other websites I have checked list every part as available but I don't know if this is realistic.)

Thanks everyone for the help!

 

I would also recommend either a pipe wrench on the outer section of the cap very carefully, or cut a small slot in the outer section of the cap and try to hammer it loose with a chisel in the groove. Pipe wrench might be a better idea to try first.. if the internal threads in the fork get damaged you might have to replace it.

Unloading the suspension & soaking the cap in penetrating oil definitely wouldn't hurt either. Make sure the air is bled from the fork first too.. not sure it would make a difference, but couldn't hurt.

Good luck!

edit: nevermind you beat me to it!

 

BikeBandit should have it on this page 1990 Honda CBR600F Parts, 1990 Honda CBR600F OEM Parts - BikeBandit.com OEM parts/ suspention/ front fork

 

The original spacers are steel. Someone has been playing in there.

 

I figured they wouldn't install PVC ones stock.

• How long are the original ones?
• If different, should I go back to the original length or stick with what was in there? (I'm 185lbs without gear)
• Is it safe to remake them out of PVC again?

Thanks!

 

Yep schedule 80 pvc make your own spacer someones been there before you for sure.