'06 Chopper bolt broken in front fork

[Got_Sum]

Well, this is odd. I noticed a gap at the bottom of my front forks yesterday on the passenger side where the front axle goes through. I looked underneath, and found a broken bolt. Below are pics. Is this just an anomaly, or signs of another issue?

 

[KaptinAmerika]

It is an indication of an over torqued bolt.

 

[Mickeetwo]

The pinch bolts should only be tighten to 12 ft lbs. Have you removed the front wheel lately?

 

[Got_Sum]

No, I have not had the front wheel off. Assuming an EZ Out will remove it? Or are they lock tited in?

 

[Mickeetwo]

Yes they should have blue loctite on them. Make sure the axle was installed correctly also. The axle should go right to left (sitting on the bike) the axle nut tightens on the left side.

 

[KaptinAmerika]

Use an end mill to flatten the broken bolt surface
Use a center punch followed by a countersink for the drill start position
Use a left hand drill bit
Heat the bolt up before trying to remove it with the EZOut

 

[wolfen]

Do all the things Kaptinamerika suggests. This same thing happened to me and I didn`t do what he suggested. The drill bit skipped from the center of the bolt and the surrounding metal is so soft that it destroyed the lower making it unusable . I had to buy a new front end, So be careful or it may be worth taking it to a machine shop and have them look at it.

 

[KaptinAmerika]

WSW will also do that type of work for you.
Most times we can even fix what doesn't look fixable to most.

 

[Got_Sum]

Kaptain, you have mail... I am almost to the point of getting a tap, and re-tapping it.

 

[KaptinAmerika]

I wouldn't recommend that
I am sitting here looking at a fork leg right now, that someone sent me, with a broken tap in it.

 

[BBChopper]

I wouldn't recommend that
I am sitting here looking at a fork leg right now, that someone sent me, with a broken tap in it.

Snap! That's gonna suck, nice hardened steal wedged in tight!:bang:
Just about as much fun as a broken easy out!!!
I used to use left handed drill bits with a centering collar that came with my snap on bolt extractor kit. 75% of the time the bolt came out with the drill bit if not the right size hole was center drilled ready for the extractor!:2thumbs:

 

[KaptinAmerika]

Pisses me off that they send it to me after they have thoroughly screwed the pooch with it but what are you gonna do. Somebody has to be really good at it I guess.

 

[BBChopper]

Pisses me off that they send it to me after they have thoroughly screwed the pooch with it but what are you gonna do. Somebody has to be really good at it I guess.

Yup, I love fixing others F up's! Sounds like a fun time for you, probably have to weld up the hole and re tap?

 

[KaptinAmerika]

I wish it were that easy but its chromed.
I have to bore the hole, core out the tap, drill the inner hole and put in a thread insert, taper the outer hole, make a tapered plug, epoxy and press the plug in then drill for the bolt hole.

 

[BBChopper]

I wish it were that easy but its chromed.
I have to bore the hole, core out the tap, drill the inner hole and put in a thread insert, taper the outer hole, make a tapered plug, epoxy and press the plug in then drill for the bolt hole.

Chromed,,, sounds like his problem he broke it he can re chrome it!:roll:

 

[FrankBDPS]

Sounds like it would be easier and more fun to finish my job! had to get that one in!

 

[KaptinAmerika]

Doh.....I just looked at it I didn't fix it yet
Geez....