Help!

Aikman666 · World Chat Champion Joined: 20 Dec 2004 Karma :

Well ive calmed down now but ive been raging all night.
Basically the allen bolt that holds the shock linkage in place on the CBR WILL NOT budge, the bolt was already rusted and partially rounded but now its well and truely FUCKED. I tried grinding down a larger allen key, no luck, tried smashing a screwdriver into it as a last ditch attempt, it took alot of pressure but then it rounded even more.

Suggestions anyone? Nomatter how mad and/or lengthy.
Drilling is pretty much out of the question.
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Sparks! · Sir Tart-a-lot Joined: 30 Aug 2003 Karma :

why is drilling out of the question?

You can get drill bit extenders from machine mart etc and similar.. ive got one that extends drill bits by about 1.5 foot! if you can get to it like that, then that might be an idea...

Other than drilling theres not much else you can do I don't think.. either take the bike apart to get access to drill it or get a bit extender..

you might want a screw extractor set too.. either that or drill the whole bolt until it crumbles then dig it out with a screwdriver Smile

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Aikman666 · World Chat Champion Joined: 20 Dec 2004 Karma :

The idea of having to re thread the swingarm (alloy) doesnt thrill me at all, and do you think my drill will make it through the bolt? Mind you this bolt supports ALOT of pressure and will be extremely tough!
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BorderHooner · Could Be A Chat Bot Joined: 29 Sep 2004 Karma :

In the past with such bolts where the threads are not able to be got at, I used to get a lump of plastercine and stick it around the bolt making a 'cup'. I'd them pour in some plusgas penetrating fluid and leave it over night.

next day, as long as the plastercine hasnt fallen off (clean the area with a degreaser and wash with plenty of hot water and dry to ensure it's grease free) the plusgas will have gotten into the thread and the bolt can them be cracked off. drill into the bolt a bit deeper so you get a good 'key' , rather than a screw driver, try an allen head screw driver bit - use a bit of solid iron bar as if you were using a chisel and hammer the bit into the bolt head, it has to be a tight fit, then with a socket on the other end of the bit, and a step up, T bar and extension, get a pry bar on the T bar and crack the bolt off. sheering the step up or cracking the socket is common.

there is always a chance the bolt will sheer.

If that doesnt work then drilling it out and re tapping is the only way, tolerance is crucial for that part so it can't be drilled out and tapped too far oversize.
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finpos · World Chat Champion Joined: 13 Sep 2005 Karma :

You'll often find that the bolt has rusted itself into the suspension link bushes as well as the threaded section, which makes it hell to get penetrating fluid or heat to and also means you need a mahoosive amount of force to get the bolt turning.

I've spent weeks trying to get rear suspension linkages apart. Not good news then.

In your boots, I'd try and find someone who can weld a big nut onto what's left of the allen head. That should allow you to but enough shove on it to shear the head off Smile

finpos.