Argh! Fork Bottom Bolt head stripped.

**Sat Nov 12, 2011 12:48 pm » Post: #1 » Download Post**

I've got a trackday at Tsukuba at the end of the month and thought I should get around to freshening up the forks. All of my experience has been with twin chamber forks (my CRF450 motard), but I knew going into this it shouldn't be any harder.

Well...

I got the one fork all apart and cleaned and ready to put back together, but the second fork was a party pooper. So I stripped the allen head bottom bolt (6mm). I even tapped a 1/4" allen into it but it only stripped it more. Keep in mind I haven't stripped the threads, but the head of the bolt.

Not sure what else to do than start drilling the head off. But what a pain since it's recessed into the fork lower.

Any other thoughts?

Dana
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2016 Husqvarna 701SM
2021 Husqvarna FS450 supermoto
2014 Honda CRF250R supermoto
1995 NSR250r MC28

**Sat Nov 12, 2011 1:07 pm » Post: #2 » Download Post**

Drill the head off. I've done a few of them. What remains of the bolt won't be tight in the damper rod.
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If I have to take the carbs off once more...

**Sat Nov 12, 2011 1:22 pm » Post: #3 » Download Post**

Roger that.

Thanks Stephen!

Dana
_________________
2016 Husqvarna 701SM
2021 Husqvarna FS450 supermoto
2014 Honda CRF250R supermoto
1995 NSR250r MC28

**Sat Nov 12, 2011 1:29 pm » Post: #4 » Download Post**

I've used a torx bit to remove a stripped out allen key bolt before, knocked it in with a hammer and then removed the bolt using a breaker bar. I used soft jaws in a bench vice to hold the fork. I dont trust my drilling enough to remain straight without going off line. Confused

**Sat Nov 12, 2011 1:37 pm » Post: #5 » Download Post**

A possibility before pulling out the drill bits. Me thinks this one got overtightened by gorilla though.

Will let ya know how it goes!

Dana
_________________
2016 Husqvarna 701SM
2021 Husqvarna FS450 supermoto
2014 Honda CRF250R supermoto
1995 NSR250r MC28

**Sat Nov 12, 2011 1:43 pm » Post: #6 » Download Post**

Try heating the bolt first as well just in case it has a bit of corrosion or if they used locktite on it. I have a nice big heavy 80watt soldering pencil for that kinda thing.

**Sun Nov 13, 2011 10:56 am » Post: #7 » Download Post**

Well, I was about to use a nice torx bit but remembered the set cost a pretty penny, so I started drilling it out. Started with 7/32", 1/4", then 8mm for the final head drilling. Sure enough, the bolt head fell out and the threaded part came out by hand!

Rebuilt according to the tuning page specs and I'm liking it already!

Dana