Fork Cap Nuts

I have new gage cups for my MK III Commando. I realize I need to put the bike on the center stand and weight off the front wheel. Can anyone tell me;
a) What size socket is the fork cap nugs? (1 5/8" perhaps)
b) Is it as simple as unscrewing the cap, replacing the cup and screwing the cap back on? That seems way too simple. :shock:

I hate surprises

calbigbird said:

a) What size socket is the fork cap nugs? (1 5/8" perhaps)

Click to expand...

= 1 5/16"

calbigbird said:

b) Is it as simple as unscrewing the cap, replacing the cup and screwing the cap back on? That seems way too simple.

Click to expand...

That's a little too simple, but it's easy enough.

After unscrewing the fork cap bolts (cap nuts), the damper rod lock nut directly below each one has to be slackened off in order to release the cap bolts from the damper rods.

You will probably have to either lower front end of the bike slightly, or raise the front wheel with a block, so that the cap bolts protrude far enough out of the tops of the forks to get a spanner/wrench on the damper rod lock nuts?

The cap bolts can then be unscrewed from the damper rods.

That doesn't sound too hard, thanks

Also, if you have an old 9/16" open end wrench, thin it down a bit on your bench grinder. This will slip in nicely to remove the damper rod from the fork nut. Some open end wrenches are a little too thick. Once you get it apart you'll see what I'm talking about.

Don W.

I have some odd and end tappet wrenches I've accumulated over the years. They'll fit almost anywhere, and a search of local pawn shops or flea markets with tool resellers will usually turn up a few.

One good one is the Craftsman #44472 1/2 x 9/16 tappet wrench. Head is only .205" thick.

pic here:

nice and long, too.

Ooohh, that's a nice set! It's always nice to have the right tool for the right job.

Calbigbird, for this application it's not hard to force the springs down enough to get what ever wrench you have available in there, then just turn the top nut off while holding the lower damper rod nuts. Eventually we all end up with our specialty thin, ground, bent, twisted or otherwise modified tools in our arsenals but in the beginning you do what you have to.

Thanks for all the information. I shall try to get that done this weekend. Hopefully I will get my tank and side covers back from the paint shop soon and I can post a few pics. This project has been more than I anticipated, but fun none the less. :lol: