Stripped Allen Screw/Front fork change

ManOfGod · April 24th, 2013, 03:45 PM

So I started changing my front fork oil and seals. I have both cylinders removed, drained, and half-disassembled. Getting to the point of removing the allen that holds the inner fork to the outer, I discover that the PO stripped one of the screws beyond recovery. The other I could not budge(I do not have an impact).

First question)How tight should those allen screws be?

Second question)Which of these options would you recommend:
First and worst)attempt to drill them out....
Second)Buy new forks....
Third)Take them in to the shop(my local guy wants $150+/- to do the job)...
Fourth)[whatever you suggest]...

Thanks--Brad

tooblekain · April 24th, 2013, 03:56 PM

If you don't have experience with an extractor, I suggest you take them to a shop...unless you can get forks for cheap...but there is no guarantee you will have the same problem you just listed...maybe ask the seller to make sure the allen bolt at the bottom of the forks are not stripped our rounded off.

Second, get an impact driver and damper rod holding tool. Right tool for the right job.

Third. The manuel recommends putting loctite. I actually am against it because it makes getting the bolt out harder. Just use new copper crush washers and torque properly and you will be good to go. If you do use loctite. use light to medium (i.e. green or blue color loctite).

In the future, if you are having trouble spray some penetrating fluid like PB Blaster Penetrating Catalyst or use some heat to help dissolve and then use an impact driver to loosen it out.

Motofool · April 25th, 2013, 12:51 PM

Quote:

Originally Posted by ManOfGod

..........Second question)Which of these options would you recommend:
First and worst)attempt to drill them out....
Second)Buy new forks....
Third)Take them in to the shop(my local guy wants $150+/- to do the job)...
Fourth)[whatever you suggest]...

I would recommend the first option.

My fourth option:

http://www.harborfreight.com/12-piec...set-40349.html

http://www.motorcyclenews.com/MCN/co...2&start-page=0

http://www.listoftools.com/broken_bolts_and_studs-3/

http://www.advrider.com/forums/showthread.php?t=674458

If red Loctite is present, you must use some torch for heat.

bruce71198 · April 25th, 2013, 01:28 PM

At this point drill it out. These bolts always seem to be really tight and have thread locker on them.

ManOfGod · April 25th, 2013, 02:04 PM

Do I just drill the head off? Will the cylider pull apart then?

bruce71198 · April 27th, 2013, 03:50 AM

Quote:

Originally Posted by ManOfGod

Do I just drill the head off? Will the cylider pull apart then?

Yes, use a drill bit that is a little bigger than the Allen key and drill till the bolt head comes off. Then slide the tubes apart. There should be enough bolt left sticking out of the inner tube to grab with a vise grip. Use some heat on it to soften the thread locker.

ManOfGod · April 29th, 2013, 01:50 PM

I took them to my uncle's auto shop. He got them out; he said they were torqued to nearly 80ft. Lb.
Should I order OEM screws and washers or not?

Motofool · April 30th, 2013, 10:43 AM

Quote:

Originally Posted by ManOfGod

.....Should I order OEM screws and washers or not?

I would.

You could also try finding equivalent bolts at any hardware store, but make sure that they have the same strength grade:

http://forums.ninja250.org/viewtopic...=853294#853294

April 24th, 2013, 03:45 PM	#1
ManOfGod ManOfGod Name: Bradley Location: Lagrange, WY Join Date: Apr 2013 Motorcycle(s): '02 Ninja 250r Scuffed and scratched blue...soon to be black, I think... Posts: 40	Stripped Allen Screw/Front fork change So I started changing my front fork oil and seals. I have both cylinders removed, drained, and half-disassembled. Getting to the point of removing the allen that holds the inner fork to the outer, I discover that the PO stripped one of the screws beyond recovery. The other I could not budge(I do not have an impact). First question)How tight should those allen screws be? Second question)Which of these options would you recommend: First and worst)attempt to drill them out.... Second)Buy new forks.... Third)Take them in to the shop(my local guy wants $150+/- to do the job)... Fourth)[whatever you suggest]... Thanks--Brad __________________________________________________ "For God so loved the world that He gave His only begotten Son that whoever believes in Him might have eternal life."-John 3:16

April 24th, 2013, 03:56 PM	#2
tooblekain ninjette.org sage Name: Matt Location: San Diego, CA Join Date: May 2012 Motorcycle(s): 2007 Triumph Bonneville; 2008 Ninja 250r (trackbike) Posts: 748	If you don't have experience with an extractor, I suggest you take them to a shop...unless you can get forks for cheap...but there is no guarantee you will have the same problem you just listed...maybe ask the seller to make sure the allen bolt at the bottom of the forks are not stripped our rounded off. Second, get an impact driver and damper rod holding tool. Right tool for the right job. Third. The manuel recommends putting loctite. I actually am against it because it makes getting the bolt out harder. Just use new copper crush washers and torque properly and you will be good to go. If you do use loctite. use light to medium (i.e. green or blue color loctite). In the future, if you are having trouble spray some penetrating fluid like PB Blaster Penetrating Catalyst or use some heat to help dissolve and then use an impact driver to loosen it out. __________________________________________________ CVMA #312SoCal TrackdaysBigHeadz RacingMotion ProFactory EffexLeatt Brace* Racetech Bell Woodcraft CFMVortexHotbodiesSurface Sun SystemsBrakingLiveWire EnergyFreegun Underwear

April 25th, 2013, 02:04 PM	#5
ManOfGod ManOfGod Name: Bradley Location: Lagrange, WY Join Date: Apr 2013 Motorcycle(s): '02 Ninja 250r Scuffed and scratched blue...soon to be black, I think... Posts: 40	Do I just drill the head off? Will the cylider pull apart then? __________________________________________________ "For God so loved the world that He gave His only begotten Son that whoever believes in Him might have eternal life."-John 3:16

April 29th, 2013, 01:50 PM	#7
ManOfGod ManOfGod Name: Bradley Location: Lagrange, WY Join Date: Apr 2013 Motorcycle(s): '02 Ninja 250r Scuffed and scratched blue...soon to be black, I think... Posts: 40	I took them to my uncle's auto shop. He got them out; he said they were torqued to nearly 80ft. Lb. Should I order OEM screws and washers or not? __________________________________________________ "For God so loved the world that He gave His only begotten Son that whoever believes in Him might have eternal life."-John 3:16

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April 25th, 2013, 01:28 PM	#4
bruce71198 ninjette.org sage Name: bruce Location: northern illinois Join Date: Jan 2012 Motorcycle(s): Race bikes:08 Ninja 250,11 R6,16 ZX6,SV650.3 HD-1947,2-2003,2010. 1946 Indian and a lot of dirt bikes.2 Posts: 999	At this point drill it out. These bolts always seem to be really tight and have thread locker on them.