crap crap crap. Mechanic advice needed on stuck nut

[jhusman]

I am trying to redo my forks, and I managed to strip out one of the filler nuts on top of the fork - totally rounded it off. I also managed to break off a "Bolt out" remover in the bolt. This is the big allen head bolt on top of the fork for those keeping score.

What can I do? This is really, really frustrating - there has got to be a way to get this out. The replacement bolt is already ordered, so I just need to get the old one out now. I tried drilling out the "bolt out" out last night, and no dice on that.

Help me Goldi - wan, you're my only hope.
Help me Goldi - wan.

[Zryder]

I know there will more presice answers here for you but first do you have all the wieght off the fork where it is fully extended ? and drained the forkoil to lessen any preasure in the forks , so just incase you do get it off and it don't fly up and hit you anywhere ? Sorry , just a couple of safety precaustions to goby first . And after if all is lost , and you cannot get that bit remover out , just drill two 1/4 " on each side of that remover , tap them for the 1/4 " bolt ,use two short bolts bolt them in use your whrench as a handle inbetween them and twist out .


My two cents ; [ Z ]

[Dave B]

FWIW -

I've had some luck in the past using a hammer and small chisel. Never tried it on this nut in particular, but it might work.

Use the chisel to create a small nick toward (even on) the outer edge of the bolt head. You want to make it deep enough that it serves as a "step" for the point of the chisel or a punch. Then drive the bolt head counterclockwise by hitting the chisel/punch at an angle. (Technically I guess it would be a tangent.)

I assume you've soaked it good with penetrating oil.

Might also try heating the threaded part around the bolt. Not sure what all is flammable in that area, or the effect on a chrome piece, so be careful before you try heat.

Anyone remember Pirsig's discussion of getting "stuck" in Zen and the Art of Motorcycle Maintenance? Think of this as an opportunity to understand your motorcycle, not as a setback.

Good luck,

Dave

[jhusman]

Thanks for the help. I am going to try to understand my motorcyle as a result fo this bolt. As Prsing says - the value of my entire motorcycle comes down to this $4.00 bolt.

[banzaiwing]

I had the same problem while doing mine. The silly hex hole rounded out. Why honda would put that small of a tool on such a large cap?? Breaking off the "easy-out" makes things a little tougher, as they are hardened steel. The only way to get that out will be with a carbide drill bit.

Anyhow, I ended up having to weld a bolt to the dang thing. It obviously ruined the cap but it came right out.

Some "HE-MAN" worked on my bike previously. Besides the fork cap, I've had to replace the diff cap and alternator cap(whenever I get the rounded one off)...............

Contact Frenchy for a new fork cap.

Or............just replace the whole fork.........

Banzai !!!!!!!!!

[jhusman]

I'm going to try drilling two holes in it first, then use my wrench as a lever. I wouldn't mind welding, but I have no equipment.

[4banger]

I have had some luck using the following procedure on some automotive bolts that were really stuck. First I heated the bolt and the area around the bolt very hot and then touched the area with a block of parrifin and let it melt into the threads. Some times this works sometimes not. The function of the parrifin is to lubricate the threads. Break the bond of metal to metal. If you try it hope it works.

[jhusman]

Well, I went out and picked up a tap last night, and I used it to put two holes in the cap for bolts. Screwed them in and it came right out. Now I can finish with my fork oil change - after I go pick up the bolt caps tonight (I went ahead and ordered two new ones).

I certainly hope after all of this work that I can really feel a difference in the way it rides.

Only a few more things to get her on the road.

[Zryder]

Glad you got it out . I know it was a kind of back yard way but it works eh ! Good Luck on the rest

[Dave B]

Ahh! Unstuck. Way to go!

Once again Quality prevails where the Church of Reason has failed.

Be the bolt.