Fork Cap Seized - Removal Tips?
I decided I was going to service the forks this weekend since I fixed enough things on the bike to finally take it for a proper ride (it was awesome), and I was going to check the spring rate since it felt like a straight rate. Loosened the top pinch bolts in the triple clamp to make life easier. The right fork cap came off no problem, but the PO must have hired a gorilla to torque down the left one. Things progressed from socket -> socket with breaker bar -> wrench -> pipe wrench with no success. The pipe wrench is starting to shred the remaining aluminum, so I don't want to take that route further and remove all the material.
The left fork cap is completely toast, and will need to be replaced. Anyone have any suggestions on how to remove the cap without possibly damaging the rest of the forks? I'm thinking I can max out the preload to move the spring as far away as possible from the cap, then drill a hole on each side of the cap as close to the center adjuster as possible to prevent getting near the threads. Then either find a small pin wrench for the holes, or tap an M6 or M8 bolt into the holes and hit them with a chisel until the cap breaks loose.
Also, if anyone has a spare fork cap laying around, well, you could say I'm in the market. I wish these things were made of aluminum that is at least marginally stronger than cheese.
2004 SV1000S - 29k miles