SuzukiSavage.com /cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> Rounded out lower fork damper allen bolt? /cgi-bin/YaBB.pl?num=1463867748 Message started by DesertRat on 05/21/16 at 14:55:48

Title: Rounded out lower fork damper allen bolt? Post by DesertRat on 05/21/16 at 14:55:48 Got a set of 30 yr old forks that "just needed a little TLC". The speedo drive side (right side) came apart no problems. But the brake side (left side) AAAAAAARRRRRRRGGGGHHHHH ... went to remove the lower allen and all my allen wrench would do was spin, thought it was the damper spinning  in the tube, NOPE ... the allen head is stripped. Tried a .5 size up allen and no love, went with an SAE allen and no love ... any ideas ???

Title: Re: Rounded out lower fork damper allen bolt? Post by DesertRat on 05/21/16 at 16:06:33 hammered a T45 star torx into it and hit it with an air impact, YES in reverse, and it didn't budge ... then decided to break out Big Bertha Breaker Bar ... sheared the head off the T45 ... and it didn't budge ... I hate loctite ... if I hit this lower tube with a torch, where should I avoid heating besides the bolt itself?

Title: Re: Rounded out lower fork damper allen bolt? Post by verslagen1 on 05/21/16 at 16:12:10 I'm guessin' this is not stock... is the head out in the open or is it buried in a hole? heat on the head of the bolt. the loctite is on the bolt and the damper, not the lower.

Title: Re: Rounded out lower fork damper allen bolt? Post by justin_o_guy2 on 05/21/16 at 16:17:30 Yeah, pay attention better. Discovering the tool is spinning after a few rounds isn't something that helps your cause. If you don't have the best penetrating oil, mix some up. 50/50 acetone and tranny fluids, easily mopped up in any redneck location women's room. Apply every few hours for a coupla days,, If you don't have a butane torch, maybe now is a good time to drop forty bucks. Clean up the allen head, shape it up with a pin punch, whatever,, JB weld the allen wrench in it. Epoxy must be Applied, not slapped on. First pass, wet the surfaces with it, a tool built to reach in and Press the epoxy onto every surface, prepare the bolt, prepare the allen wrench, put it together with the allen head just loaded up enough to force the epoxy out some. If you have an impact, even if you don't, you're probably ahead to cut the allen wrench off, just use a piece long enough to do the job. A socket will work. An impact on a piece epoxied in would be better. Heat the bolt up first, several times. The Hot spot of the flame is the tip of the center cone. Ice, applied to the outside of where the threads are helps shear the corrosion. Antisieze is good going back. Ohh, don't forget to remove the pinch bolt that Keeps the axle keeper..

Title: Re: Rounded out lower fork damper allen bolt? Post by Armen on 05/21/16 at 16:59:36 Or, Drill into the center of the Allen with progressively larger bits until you drill the head of the Allen bolt off. Then slide off the lower leg, put the damper in a vise with soft jaws, and put Vise Grips on the remaining nub of the Allen bolt. -Armen

Title: Re: Rounded out lower fork damper allen bolt? Post by DesertRat on 05/21/16 at 19:09:12 Vers, these are s50 forks ... same guts and specs ... Justin, IT WAS ALREADY STRIPPED ... @$$#@t I din't know ... none of my allens would fit because it was rounded out ... my guess is why they were so inexpensive. Someone else had already been there done that and sold the leftovers ... not really interested in JB welding anything down that hole into the head ... Armen, thanks for the heads-up, after the torch, the easy-out (extractor) or the head removal was my next steps ...

Title: Re: Rounded out lower fork damper allen bolt? Post by LANCER on 05/21/16 at 19:35:16 Will be praying for you.  8-)

Title: Re: Rounded out lower fork damper allen bolt? Post by Dave on 05/22/16 at 05:13:25 Is the torx head now broken off and stuck in the bolt?  If the hardened torx head is in that bolt head...you won't be able to get a drill to do anything. If not....drilling the head off is your best bet at getting the forks apart.

Title: Re: Rounded out lower fork damper allen bolt? Post by justin_o_guy2 on 05/22/16 at 07:28:07 Again, some forks have a bolt that makes pulling the axle retainer impossible..

Title: Re: Rounded out lower fork damper allen bolt? Post by justin_o_guy2 on 05/22/16 at 07:30:13 Inspection, oil, patience, heat, and hopefully the busted Torx will come out.

Title: Re: Rounded out lower fork damper allen bolt? Post by DesertRat on 05/22/16 at 11:16:57 the Torx bit sheared off, it's out and I'm still left with the rounded out OEM hex head stuck in the fork. I filled the cavity with Mistic Metal Mover and let sit last night. This morning, I got out the torch and heated up the stuck bolt only, in hopes of breaking the loctite bond.

Title: Re: Rounded out lower fork damper allen bolt? Post by DesertRat on 05/22/16 at 12:08:43 Thanks to the girl standing behind me praying while I hit it with an air impact ... it broke loose thank you G*d ...  :) Faith without works is dead ...

Title: Re: Rounded out lower fork damper allen bolt? Post by justin_o_guy2 on 05/22/16 at 13:15:22 It Worked,  that's what matters.Good going. And give the girl a hug..

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