Fork Pinch Bolt (Allen Head) truly fubared.

[iMark]

https://i.imgur.com/88idr1B.jpg

So, the fork seals are shot and I have my MOT in just over a week and I can't get this bloody pinch bolt out...

Tried hammering progressively bigger torx bits in and it still won't turn (it's been done up way too tight, a lot more than the manufacturers recommended 20nm!)

Trying to turn it just strips it out further or the torx bit doesn't want to grip inside.

Tried hammering it with a big flat head screwdriver to break it loose and it's still not budging even after several good whacks with a hammer at an angle to knock it counter clockwise and still no luck.

Any ways onto my actual question
Would welding a nut on to the top of the pinch bolt work or is that just going to snap the head off it?
Or would I be better drilling the head off it and drilling a smaller hole in the actual thread once the head is off the bolt and forcing a another torx bit into the threaded part only?
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K8 GSXR 1000
"G" : you got him to have a look at a forum which seems to have established a picture of an erect penis in a cat's mouth as it's mascot and thought he might consider it ok?

[CaNsA]

One of the two will always be easier to undo.

If the one on the left is super tight, then the one on the right will be less tight. Unless you do them up at the same time.

Try tightening the one on the right a tiny bit, then give the left one another try.

[P.]

If you not manage to get it out and MOT time comes round... fit some gaiters. Don't remove the forks, just cut plastic gaiters vertically, wrap around fork, compress and cable tie them top bottom and 2 in the middle.

Obviously you'll need to sort the seal but will buy you some time and keep you on the road

[........................]

I'd go for a left hand drill bit but then I've got a set. A worthwhile investment if you plan on working on bikes.

[iMark]

I bought some of these neoprene fork savers to do that Paddy, but I still need to take the forks off the bike to get them on which I don't have a yoke paddock stand for that, so I may resort to just laying the bike on it's side while I take the front end off the bike to get them on.

Obviously I don't want to leave the fork seals leaking though


Tried tightening the other one, no avail, hammering it is just cutting the head off the bolt
https://i.imgur.com/q5VoWXR.jpg
https://i.imgur.com/Tpi9My5.jpg
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K8 GSXR 1000
"G" : you got him to have a look at a forum which seems to have established a picture of an erect penis in a cat's mouth as it's mascot and thought he might consider it ok?

[P.]

Got car jack? Block of wood under sump, jack up, axle stands under engine. Boom.

I'm too lazy to get full on stands to do so.

[stinkwheel]

[Fisty]

Heat. Lots of heat..
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Quietly and consistently taking the piss.
TL1000R | Hayabusa | ZXR400 | TL1000S | Bandit 400 V
Fatter and faster than Fret

[iMark]

I wish I had a car jack

Kind of stuck with primitive techniques for this one..

Don't have any thing that can heat it up either the torch I had decided to stop working!

Using a normal RH drill bit from the wrong end makes a bit of sense

Don't think I can hacksaw it from underneath stink, the bolt isn't fully exposed from underneath, half of it is still inside the alloy casting of the fork, but I have had WD40 sprayed on it from all angles a few days ago from the head, underneath and at the back.

Hammering it after trying to tighten the other bolt didn't work, I'm actually cutting off the head of the bolt trying to get it undone that way


EDIT:
Wait a minute, I understand what you mean by hacksawing it now, cus of the grove in the actual pinch part of the fork
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K8 GSXR 1000
"G" : you got him to have a look at a forum which seems to have established a picture of an erect penis in a cat's mouth as it's mascot and thought he might consider it ok?

[Vincent]

[stinkwheel]

[iMark]

Yeah, I figured that out after reading it again and edited the post hehe

Will give that a shot, dunno if I'll attempt that tonight though as it's starting to rain
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K8 GSXR 1000
"G" : you got him to have a look at a forum which seems to have established a picture of an erect penis in a cat's mouth as it's mascot and thought he might consider it ok?

[SQL]

lift dust seals and use a seal mate, if that doesn't work get to MOT station ten mins early then kitchen roll under the dust seal replace dust seal

[iMark]

Pinch bolt no longer has the grip of death, Cut through it with a hacksaw blade... Only took about an hour cus of the tiny bit of movement I could do

So I should be able to get the axle nut thing off from that side now to get the fork seals done

Will remove the rest of the bolt when I get chance, one pinch bolt is enough

Currently it's not letting me pull it out, it's just turning the hole , pliers won't grip it very well in that position so it can stay there for now!

Big thank you for that suggestion Stinkwheel

https://i.imgur.com/ZDr7mBH.jpg
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K8 GSXR 1000
"G" : you got him to have a look at a forum which seems to have established a picture of an erect penis in a cat's mouth as it's mascot and thought he might consider it ok?

[CaNsA]

[Vincent]

If you get a drill onto that stud now....it should just screw out.
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Space Is Deep

[iMark]

both parts of the bolt are still in, the part with the head is turning but won't pull out with pliers, so I can't get a drill in to thread the other part out at the moment.

Will need to wait for daylight to remove it
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K8 GSXR 1000
"G" : you got him to have a look at a forum which seems to have established a picture of an erect penis in a cat's mouth as it's mascot and thought he might consider it ok?

[Raffles]

Don't forget to tell the lawyers that it was Stinky who suggested that you hold everything together with Blu-Tack.
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A good loser will always be a loser.

[1cyl]

Glad to see progress has been made .
Perhaps now you could try and gingerly knock the tip of a sharp flat head in underneath the head of whats left of the bolt, for leaverage while attempting to wind it out.
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Chase my Witch up, Catch my Snitch up.
The SMC | The Pit | Stable

[bugeye_bob]

I know it needs to come out one day but id have borrowed a trolley jack and bit of wood to support the bike and just changed the fork seals with the wheel attached, drop the forks out the yokes and do what you need to do,
Gets you sorted safely for the MOT with no risks imo.

[Vincent]

It's just the burr from where you cut it that's stopping the head coming out. Start levering it out from the inside then you should be able to get a screwdriver under the head.
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Space Is Deep

[iMark]

[Kickstart]

[stinkwheel]

[merquis00]