41mm Fork Plug Removal Tool

[Okanagan]

The F650 and 700GS 41mm forks have plugs at the top that are under spring pressure and retained by a circlip-like retaining ring. The plug has to be pushed down against the spring to access and remove the retaining ring. There are various McGyver ways to do this but I decided to design and 3D print a tool for the job.

 

[Extechin]

Was the spring tension particularly high for you as well? I used a larger punch for this, pressed the stopper down, and removed the spring clip using needle-nose pliers.

 

[Okanagan]

Was the spring tension particularly high for you as well? I used a larger punch for this, pressed the stopper down, and removed the spring clip using needle-nose pliers.

The spring tension was not that high but strong enough that I would rather keep it under control while manipulating the retaining ring.