Fork Plug

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2cycle
Posts: 178
Joined: Wed Jun 22, 2011 1:33 pm
Location: N.S. Canada

Fork Plug

#1 Post by 2cycle » Sun Nov 19, 2017 10:53 am

I can't seem to push down the fork plug (350lc)far enough to remove the retaining clip. It will only move a tiny bit and then it feels like something is stopping it.......Any ideas ?
1973 ct70
1974 xr75
1977 rd400
1981 rd350lc
2002 zrx1200

hondaror
Posts: 2828
Joined: Mon Mar 03, 2014 8:44 pm
Location: Alberta, Canada

Re: Fork Plug

#2 Post by hondaror » Sun Nov 19, 2017 1:47 pm

Yeah, there could be a load of preload spacers in there, making the task extremely difficult. Try using a deep socket to push it down with the but of your hand.
Rory
2 1984 RZ350s
1985 RZ350
9 1986-1990 RZ350s
2000 ST2
2005 749
2005 749 with 999 engine

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two-stroke-brit
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Re: Fork Plug

#3 Post by two-stroke-brit » Sun Nov 19, 2017 2:34 pm

or get a buddy to help .
350LC,Athena 392 big bore,stock porting,swiss cheese air box,stock reeds,spec11 pipes.(now TSA big bore pipes)
She might not be pretty but she will always be a fun ride


1982 YAMA RD350LC
98KDX 220R
1967 TRIUMPH TIGER
2001 TRIUMPH TT600

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Zedixe13
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Re: Fork Plug

#4 Post by Zedixe13 » Sun Nov 19, 2017 9:20 pm

I had the same problem when I tried to save a plug from a rusted tube good for the bin , I finally cut the tube to relieve the pressure from the spring , dirt under the cap was the culprit .

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2smoke
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Re: Fork Plug

#5 Post by 2smoke » Mon Nov 20, 2017 12:37 am

Maybe the O-ring is stuck. Try wd-40 or some creeping oil overnight.
Or adding heat.
Colin
79 RD400F Daytona Special
81 RD350LC
89 TDR250
75 Kawasaki H1 500
77 Can-am Tnt250

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JonW
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Re: Fork Plug

#6 Post by JonW » Mon Nov 20, 2017 7:50 am

I had same as Zed and cut the end off one...
80 XT500 Supermoto!
81 RD350LC Resto
82 RD421LC Hybrid
82 RD350LC decapitation project
82 RD250LC JDM '251LC' YPVS
83 RZ350 Resto
84 RZ500 Resto
85 RZ350 F1 Resto
86 RZ350 F2 Resto
86 RZ350 F2 Hybrid

Like Watches? www.PloProf.com & www.DeskDivers.com

2cycle
Posts: 178
Joined: Wed Jun 22, 2011 1:33 pm
Location: N.S. Canada

Re: Fork Plug

#7 Post by 2cycle » Mon Nov 20, 2017 8:22 am

Thanks for the tips....... I got it out eventually but the plug would only push in just enough to get the retainer clip out with no extra room.
1973 ct70
1974 xr75
1977 rd400
1981 rd350lc
2002 zrx1200

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two-stroke-brit
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Joined: Fri Nov 22, 2013 10:49 pm
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Re: Fork Plug

#8 Post by two-stroke-brit » Mon Nov 20, 2017 3:29 pm

2cycle wrote:Thanks for the tips....... I got it out eventually but the plug would only push in just enough to get the retainer clip out with no extra room.
so what was taking up the space beneath it ?
350LC,Athena 392 big bore,stock porting,swiss cheese air box,stock reeds,spec11 pipes.(now TSA big bore pipes)
She might not be pretty but she will always be a fun ride


1982 YAMA RD350LC
98KDX 220R
1967 TRIUMPH TIGER
2001 TRIUMPH TT600

2cycle
Posts: 178
Joined: Wed Jun 22, 2011 1:33 pm
Location: N.S. Canada

Re: Fork Plug

#9 Post by 2cycle » Mon Nov 20, 2017 3:54 pm

once I got the forks disassembled I tried pushing the plug into the fork stanchion with no spring and it still would only go in just enough so the top of the plug was just past the groove for the retainer clip. I'm sure when I changed the fork oil years ago I could push the pugs in a lot further.
1973 ct70
1974 xr75
1977 rd400
1981 rd350lc
2002 zrx1200

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two-stroke-brit
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Re: Fork Plug

#10 Post by two-stroke-brit » Mon Nov 20, 2017 6:32 pm

2cycle wrote:once I got the forks disassembled I tried pushing the plug into the fork stanchion with no spring and it still would only go in just enough so the top of the plug was just past the groove for the retainer clip. I'm sure when I changed the fork oil years ago I could push the pugs in a lot further.
strange eh :smt023
350LC,Athena 392 big bore,stock porting,swiss cheese air box,stock reeds,spec11 pipes.(now TSA big bore pipes)
She might not be pretty but she will always be a fun ride


1982 YAMA RD350LC
98KDX 220R
1967 TRIUMPH TIGER
2001 TRIUMPH TT600

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JonW
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Re: Fork Plug

#11 Post by JonW » Tue Nov 21, 2017 1:59 am

probably rust or gored the ID of the tube at that point :(
80 XT500 Supermoto!
81 RD350LC Resto
82 RD421LC Hybrid
82 RD350LC decapitation project
82 RD250LC JDM '251LC' YPVS
83 RZ350 Resto
84 RZ500 Resto
85 RZ350 F1 Resto
86 RZ350 F2 Resto
86 RZ350 F2 Hybrid

Like Watches? www.PloProf.com & www.DeskDivers.com

2cycle
Posts: 178
Joined: Wed Jun 22, 2011 1:33 pm
Location: N.S. Canada

Re: Fork Plug

#12 Post by 2cycle » Tue Nov 21, 2017 8:43 am

Had a good look and found that's as far as they can go......there's a lip on the plug that hits a lip on the inside diameter of the fork tube.
1973 ct70
1974 xr75
1977 rd400
1981 rd350lc
2002 zrx1200

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JonW
Posts: 10599
Joined: Sat Oct 10, 2009 4:33 am
Location: Sydney
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Re: Fork Plug

#13 Post by JonW » Tue Nov 21, 2017 5:31 pm

Oh? Im sure mine went in about 1/4" past the ring groove.
80 XT500 Supermoto!
81 RD350LC Resto
82 RD421LC Hybrid
82 RD350LC decapitation project
82 RD250LC JDM '251LC' YPVS
83 RZ350 Resto
84 RZ500 Resto
85 RZ350 F1 Resto
86 RZ350 F2 Resto
86 RZ350 F2 Hybrid

Like Watches? www.PloProf.com & www.DeskDivers.com

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