Front forks on a 200s problem

[DeePa]

Thanks to Huffa, i finally got my forks apart and everything looked good to go. Unfortunately, i stupidly ruined one of my fork seals. I bought 2 new OEM ones, and now all thats stopping me is the 6 mm alan screw which somehow holds the upper tube into the lower tube.

its # 20 on this...

http://houseofmotorcycles.bikebandit..._id~191105.asp

Well I tried and tried to get it out, and with my brand new set of alan wrenches, i ended up stripping the alan wrench head. I took a drill, drilled about 1/4-1/2 inch down the center of the screw, slammed an easy out in there, and tried to remove the screw...SNAP...there goes the easy out. I called it quits because i was out there since midnight until 2:25, and i just gave up on it.

Last night, i put both forks upside down into the vice, and filled up the whole area where those screws are with PB blaster screw loosener. Even still, they were a ***** to move, and i didnt get them. I didnt try on the second fork because i was sick of it. I took the blow torch, and used it for about 20 mins off an on, then 20 mins straight to try and loosed up the gunk thats probably holding the screw in there. I know heating stuff makes it expand, but it also loosens and breaks down the 20 years of grime which is holding the screw like theres no tomorrow.

So i am basically asking what do i do next? Take it to a friends machine shop and just hope he can get it out, or go to the stealer and get robbed. (they told me a price of 120 + ATF for servicing both forks, and wouldnt just take the top retaining clips out which you were supposed to use a hydraulic press on, because i could *hurt myself* and it was a *liability* for them...oh well)

What should i do? What can make this **** come out?

Please help me out.

Mike

[wheelie king]

That sucks......

IF you have a friend with good metalwork skills and a machine shop, I'd try that before the stealer. Gently try and get that sucker out. Just be careful, because as you've learned, you'll break stuff without trying, and then you'll be left with no options. Use the torch sparingly (I think) and be patient. Good luck.

[bigredhead]

E-bay !!

Look for a new set !
( considering everything you've tried so far !!! )

Those suckers would'nt have reverse thread would they ?

[DeePa]

good idea, already found one set...maybe if i can pick them up for a total of 40 bucks should be good.

I am going to the machine shop now, because i feel thatll be a cheaper option.

Thanks guys,
Mike

[Huffa]

As long as the allen hole didn't get messed up you need an impact to really give it a quick jerk. From the factory i think there is usually super thread lock on them which makes it really hard to take off.

Don't feel bad, I ran into that too already.

If the bolt just spins & spins without coming loose that means the damper rod it attaches to is spinning also. There is a speacial tool to hold the rod from spinning that you put down in the upper fork tubes.

Just go to the Honda dealer and ask them to break them loose for you if the rod keeps spinning.

I have not yet taken them apart on the S I am working and won't unless the fork seals are leaking. If I do, I'll let you know how it went.

[DeePa]

nah the alan wrench hole is stripped...perfectally round. THen i smartened up and bought a 6mm socket, threw it on the torque wrench, and the other one cam eout fine.

Only bad thing is the other on is at the machine shop, and hopefully he will get it out before i the forks on ebay have ended