Topic: Very stuck fork caps, '82 Yamaha xt 200

[westernvistas]

On a break from my 550k, I'm trying to rebuild the forks on an '82 yamaha xt 200 and cannot for the life of me get the damn caps off! They are inverted from usual caps, with space to fit a large allen wrench. After several days of PB blaster and wrenching, I have made no progress. Have also tried some impact and a little heat. Any ideas?

[kirkn]

IIRC, my Yamaha XT200 caps were held in by a circlip that was recessed in a groove below the top of the cap.  You had to press the cap down into the fork (against the fork spring's tension) to expose the clip with one hand, then with your other two hands, pry the circlip inwards from the fork leg (the clip springs outward "into" the inner diameter of the fork tube).  Then release the cap and it springs out.  No threads or anything.

Good luck.

Kirk