Exactly the same as the one I made for my ZZR

Cheers for the replys.

I brought a 2' hand impact wrench(one you whack with a hammer) and some 1/2" Allen sockets. Heated up both the bolts with a blow torch. Got my mate to compress the fork whilst i whacked the wrench. The first one cracked and came out no problems, but the second one rounded.

Any thing i can do to get it out or is it time for some new forks?

Cheers for your help.

Try hammering a slightly bigger torcx bit into the allen bolt head then your impact driver to turn it. either that or drill the head of it and you might be able to remove the rest of the bolt with a vice or mole grips once you get it out, then you only need a new bolt.

There was one way that I tried when the bolt rounded and wouldn't shift. It was on a Beemer R80 fork leg.

As there was a fair bit of space round the bolt head, I hammered in a cut-off allen key then ran a bead of weld round the join between the allen key and bolt using a thin gauge rod in the arc welder. The combination of heat followed by rapid cooling was enough to free it off. I had a spare set of forks if it all went t**s-up anyway
A bit savage? Yes, but it was preceded by a good few trial runs with the welder off first to see if it was a go-er!

Compressing the forks doesn't do anything. If you pull them apart you collapse the top-out spring against the cartridge lip, which has a chance of creating enough friction to stop the cartridge from turning (but an air ratchet is the sure way of getting the buggers out)...

Ciao,

JZH
London, UK/So.Cal., USA
http://www.vsource.org

Windy gun fitted Snap On deep impact 3/8 drive allen bit every time - never fail - if rounded use small air driven pistol drill with new cobalt bit / cutting oil - 2 mins max.

We have hundreds of old internal fork bits if you need used bolts etc.

Hope that helps.

Graeme