HELP! ATC 250r fork allen remove please READ

[trikeguy2014]

First of all i know there are several post about this and i have read them all and tried everything i read
I have tried air gun with someone compressing full assembled
Broom stick down trying to hold it
Last resort i put wheel back on hooked two rachet straps around the front axle and full compressed the springs and hit it with air impact and nothing seems to work
even tried to heat it up

ANY Other ideas would be great to keep it from spinning on the other side

PS other allen bolt from other fork came right out

[christph]

My Tecate has a recessed hex nut pattern in the top of the slider. I used a threaded rod with two nuts tightened back to back (on both ends), insert one end in the top of the slider (with the appropriate size nut), and hold the other end with a wrench while someone loosens the allen bolt. It has been a while since I worked on my 250R so I can't remember if it has the same recessed hex pattern. You might check with a flashlight. If worse comes to worse just drill the allen head off. An allen bolt is easy enough to replace.

[RoscoW]

I've drilled a couple out as well. The allen head centres the bit perfectly and as soon as you get to the threaded portion the head spins like drilling a pop rivet.

Ross..

[Red Rider]

If the allen bolt is spinning now, it'll be difficult to drill.

[trikeguy2014]

If I try and drill it out I take it I will have to retap the threads... Will they tap okay I know some metals don't take well to being retapped

[jb2wheels]

I heat the bolt up with my propane torch.
Heating the bolt turns the thread locker on the bolt to goo.
Also, the aluminum chunk the bolt threads into expands more than the steel bolt.
Then hit it with the impact wrench.

But I imagine you tried that already.
I never had to drill one out. Shouldn't be too bad to drill the head off the bolt without trashing the threads. Need a big bit then leaves the shank/threads in the guts to work out later once you get the fork apart.

[trikeguy2014]

Okay that's what I was thinking maybe just drill the head off so I can continue and get the fork apart and maybe then get the bolt out without messing the treads up... I am going to continue trying tomorrow so I'll keep you guys updated

Also any other suggestions would be great

[christph]

I'm not sure you are understanding the option of drilling it out. The only thing you are drilling a hole in is the head of the allen bolt, not the bottom of the fork. Find a drill bit just a bit larger than the hex hole already in the allen bolt. Do your best to estimate the diameter of the threads and that's the size bit you want. Drill down only a bit beyond the depth of the hole until you get to the base of the head; stop before you hit the aluminum fork. With the head weakened, you can use a punch to separate the head from the threads. The bolt does not thread into the fork, it threads into an aluminum insert on the other side that should pop out once you break the head off with the punch. You will not have to re-tap any threads. You will only need to replace the allen bolt.

[trikeguy2014]

Got it done today! I ended up drilling the allen head off taking the forks apart and I just put some vise grips on the bolt treads that stuck out heated that piston up and finnaly broke it loose... Found the problem whoever rebuilt that fork in the past went little crazy on the tread locker... But anyway a new bolt, seals, fork oil, fork boots should be ready for the summer riding season... Thanks for the replies

[YTZ drew]

I don't know what everyone else here does, but I use liquid pipe thread sealant (sparingly) instead of loctite on these fork bolts. Seals nicely, and you don't have disassembly problems in the future.

[shortline10]

Map gas on the Allen bolt for about 30 seconds and a snap on 1200 lbs impact works every time for me .

[3wheelrider]

Map gas on the Allen bolt for about 30 seconds and a snap on 1200 lbs impact works every time for me .

^^^^^^^^^Mike bailed me out with this method- I had the same exact issue with my R- Had Loctite on mine as well. Softened rite up with the heat. The badass airgun helps too..lol

[RoscoW]

Mine wasn't so much a loctite issue but rather a P.O using the wrong size allen key an rounding everything out……enter the drill it out method.

Ross..