Super tight rear upper shock bolt removal - noob

[froudy]

When you do finally get it out DO NOT use a cheap made out of cheese, Chinesium tap to clean the threads out. Use a good quality one..Don't bodge it!

[SA14]

https://www.facebook.com/captainthread/

'We are a fully mobile business operating in South Australia, Adelaide and metro suburbs. We specialise in Broken bolt removal , thread repair, sump plugs, head bolts, spark plugs, brake calipers, bleed screws, helicoils , keyserts, repair , we can also help you add a thread for extra oil cooler line, coolant line. We cater for Industrial, automotive, private, you name it , if it's got a bolt ,a thread and it snapped, or no longer holds. we can fix it, we use only quality helicoils, keyserts, bigserts.'

Leave it to the pros and return your man card.

[steve porter]

Damm

[VladTepes]

Ok so I'll add -

Avoid easy outs as if they break then you have a much bigger problem than you started with.

Don't use grease in lieu of coppaslip or nickelslip.  Just use nothing until you can get some.

You don't need loctite but if you do, just use some blue (243) Loctite - sparingly. You don't need a lot.


If you happen to have red loctite - throw it away now.  Its a danger to everything.

[SA14]

Got lucky! It's out.

1) Grind off remaining bolt head
2) Remove shock (swing it out of the way after loosening the "tail body work" (noob...lol)
3) Grind bolt down until no hole (or old drill bit) is left. Luckily the bolt was far enough out to do that.
4) Drill tiny hole (because where the hell is my centre punch!)
5) Drill larger hole until drill is so blunt it won't dril anymore (using WD40 in the absence of proper cutting paste)
6) Insert easy out and swear at it with a warning
7) Battle with extremely poor quality tap holder (gave up - wouldn't grip the square end) and start carefully and gingerly trying to screw it in (backwards of course). Felt something turning but couldn't see what. Get torch to see what was turning and low and behold the bolt started to squeak loudly but... turn it did.
8) Extract and swear very loudly at it. Threads look good inside!
9) Find M8 1.25 pitch tap and turn it into the hole by hand. It turned quite easily but about half way through I had to get my little shifter to turn it all the way to the end.
10) Try original bolt from the other side and it screwed in easily with fingers. Proceed to next level of excitement
11) Try Chunnings gold high tensile bolt. Screwed in easily.
12) Replace shock, screw in new gold bolts, tighten to two grunts.

Back away slowly then re-apply for a temporary man card.

Thank you everyone!

P.S. Machines need blood to live so yep, I was correctly injured during the procedure as per the manual.

P.P.S. Why cheap and shit tools? Lost everything I ever owned in a financial catastrophe a few years ago. Just now getting back on me feet and buying essential tools only from Chunnings until I can afford a proper precision set of tools again.

[gsxbarmy]

Wow @SA14 good result!!!! And what a relief as well. Glad it all came good in the end

[VladTepes]

Cool.

Now if you wish to make your life even more rewarding - move to Brissie !

[KiwiCol]

Good on ya SA14, glad it came out.

[Kiwifruit]

Hope you signed the Health and Safety book after that severe paper cut.
Can't believe you didn't identify that little hazard 

Good result in the end.

[Hooli]

Good result.

If you're not refitting the rack I'd put a bigger washer on it, from memory the 'mushrooms' that normally go that are as wide as the 'loop' on the top of the shock. That holds it all in line so the bush won't tear.

[Mick_J]

Well done SA14, good job.

[Eric GSX1400K3]

 :salute:well done  like Hooli says, please put a bigger washer in behind the head of that new bolt.

[SA14]

Wow @SA14 good result!!!! And what a relief as well. Glad it all came good in the end

Total relief! Perfectly said. My smile was broad this afternoon. You guys all helped which is love old school forums so much. On Facebook this would have been buried in a few minutes. Facebook does the impossible. it both blows and sucks at the same time.

Cool.

Now if you wish to make your life even more rewarding - move to Brissie !

Too humid for me. Plus you guys are just a little bit crazier up there. My theory is it's because you don't get seasons...lol Discuss. 

Hope you signed the Health and Safety book after that severe paper cut.
Can't believe you didn't identify that little hazard 

Good result in the end.

The cut was from slipping on the spanner...as it should be. No blood though which is a shame because I always wipe some of my blood onto every vehicle somewhere so I can really claim ownership but now with this kickback from the 14 I feel satisfied that it's "my bike" now.

and Thanks.

Good result.

If you're not refitting the rack I'd put a bigger washer on it, from memory the 'mushrooms' that normally go that are as wide as the 'loop' on the top of the shock. That holds it all in line so the bush won't tear.

Ah, that makes sense. I copied the washer from the existing bolt but now that you've informed me it's an incorrect bolt I'm not surprised it's not the right washer either. I'm not sure I'm totally in love with the gold finish because everyone knows where they come from and what they are. I'll try and source a proper bolt with a nice dome head and get a proper fat washer too. Thanks for the tip.

Well done SA14, good job.

Thanks. I hope it helps someone else at some point in the future. That's why I wanted to heavily document my tiny struggle because I've been helped by heaps of threads on here already. Working my way through every thread. Better than TV.

:salute:well done  like Hooli says, please put a bigger washer in behind the head of that new bolt.

Yep, noted and will do. Just on this, is ok to ride like this on the weekend? I've only ridden this thing once - not counting some slow tight corners around the backyard the other day...lol. Need to put some triple digit kms on it because it's also got 3 year old petrol in it.

But seriously, I know I've said it a lot but thanks forum. You guys rocked so now I can roll.

[SA14]

Is there anything more noble than stopping to help a newbie? 

[Eric GSX1400K3]

Id be draining that 3yo fuel out quicksmart  fill with nice new 95Ron and a bottle of petrol injector cleaner and go for a fast ride AFTER fitting the correct washer.

Theres a thread on here about the nightmare that is off fuel and the havoc it causes to the fuel tank and efi system.