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Front Caliper Bolt

Discussion in 'XJ Technical Chat' started by osprey1000, Nov 23, 2012.

  1. osprey1000

    osprey1000 Member

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    So since it has become too cold up here in Upstate NY to keep commuting on the bike I have taken to Restoring/Sprucing it up some. Taking care of the basics. Brakes being the fore-front. Started on the rear. Took the tire off and the brakes are ok back there. Polished up the brake cover to a mirror, and cleaned everything up while I had the tire off. So I have moved to the front to begin the process for the front brakes. And I pulled the big stupid. In the process of taking the bolt off to get the caliper off, I had no idea that someone had put in WAY (not enough emphasis on that word) too much thread lock on that bolt... So in pulling it off I of course snapped the bolt. Which brings me to my question. Anyone have a good way to get the rest of that bolt out without destroying the tread in the fork? There is about 1/4" of the bolt still showing. Should I just try heating the fork and grabbing the bolt with some Vise grips?

    Any advise would be appriciated. Really hate to screw up the fork because of my in-patience...
     
  2. MiCarl

    MiCarl Active Member

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    It's got a lock nut on top. You did remove that??
     
  3. hogfiddles

    hogfiddles XJ-Wizard, Host-Central NY Carb Clinic Moderator Premium Member

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    Osprey,

    First....I'd almost bet that you didn't loosen the top lock nut before trying to remove the bolt. You can either remove the rim to access it more easily, but if you are methodical, you can insert a wrench (I THINK it's a 12mm on that, may still be 10mm) through the one of the rim's wide gaps, rotate the rim back and forth a few inches so that you can articulate the wrench to 'loosen' the nut. I bet that as soon as you do that, you can grab the rest of the bolt with some vise-grips, and then remove the top nut and then turn the rest of the bolt out. The bolt is threaded up there, so you'll have to keep turning it out, you can't just pull it straight out.

    Another option if that doesn't work.....if you pull the front rim off, loosen the two pinch bolts for the upper fork tube then you can hop in your car and bring it down and we'll see what we can do. I have an extra left fork that I got in a bit ago, and could swap you if needed. Car?--Oh yeah---I'm only about 50 min or so from you. A little below Utica, or if you're coming across 20, about 6 mi off of 20.

    Also, I host a carb clinic every June, if you're interested let me know and I'll start forwarding info to you as I start to develop stuff for this coming spring.

    I'd suggest that that if you're doing that much detailing.......pull the front rim to do the nut/bolt thing, and you can strip, sand, and re-clearcoat the fork lowers before re-assembly. That'll make the front look AWESOME.

    PM me................

    Dave Fox
    host, Central New York Carb Clinic #6-June 2013
    owner, Central New York XJ Shim Pool
    Registrar, XJ900RK (USA-Delivered) Seca Registry
     
  4. Maxim-X

    Maxim-X Well-Known Member

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    Hogfiddles, it's guys like you that make this forum what it is. Helping a forum member that is in the neighbourhood (sorta) ;-) osprey, sounds like a great offer.
     
  5. OzRoadbandit

    OzRoadbandit Member

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    I'd probably try an ezy out on the bolt before mashing the remainder of the bolt.
    If the bolt is really screwed, drill it right out and use a helicoil. These are absolutely straight forward to use and leave you with a perfect thread.
     
  6. hogfiddles

    hogfiddles XJ-Wizard, Host-Central NY Carb Clinic Moderator Premium Member

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    There's really nothing to mash.........he's broken the bolt, so it needs to be replaced. But like I said, my bet is that he didn't remove the lock nut from the top first. That being the case, all that has to be done it to remove the nut, and the remainder of the bolt can be removed.

    We'll see......

    Dave F
     
  7. osprey1000

    osprey1000 Member

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    First of all I have to second Maxim-x's statements. It is nice to know that I have a plethora of knowledge right down the road. And so willing to assist. As you suspected Hogfiddles, I didnt loosen the top nut. So when I get off work tonight I will have to head back out to the shed and see what I can do with that.

    And thanks for inviting me to the carb clinic. I was at some point going to PM you about that. Unfortunately it may be long after I have learned these carbs inside and out since by the time that I had put the bike up for the winter the thing was haveing a really hard time running. So as soon as I am done with the front end the next step will be the carbs coming off. Something that I know I need to do, just dread doing it. And of course (I hear all you reading this screaming already) as soon as the carbs are off, The valve cover is coming off as well to check them. But I may still take you up on it anyway, since you can never know too much :)


    To your point about the front forks. The whole start to this polishing was Rick's Maxim. So I intend to polish the forks and motor while I am working on it to get that chrome look all over. We shall see what I can make happen. I am sure it wont look as good as his when it is finished.

    Thanks again and I will keep ya posted once I get home tonight and can get to work on it!
     
  8. Maxim-X

    Maxim-X Well-Known Member

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    Lets see:
    Location, check. Bike info, check. Listening to advice, check.
    Osprey, you are going to do just fine here. 8)
     
  9. hogfiddles

    hogfiddles XJ-Wizard, Host-Central NY Carb Clinic Moderator Premium Member

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    well!?!?!

    dave
     
  10. osprey1000

    osprey1000 Member

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    Yeah sorry about that Dave, Got home from work last night late and with the wondeerful weather we are having going out into an uninsulated shed was not happening. So I stayed in to work on the exhaust, which hopefully I can get some pictures of tonight to show off. We will see how the last coat of paint dries. Tonight though my fiance is home so I will have her go out and turn on the space heater when I leave work so it will be nice and toasty warm when I can get home. Will keep ya posted.

    In the meantime though I thought I would show you some of that detailing work that I did to the rear, which is just the start to the rest of the bike.
     

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  11. hogfiddles

    hogfiddles XJ-Wizard, Host-Central NY Carb Clinic Moderator Premium Member

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    Uh.....you ARE gonna polish the brake stay mount, right?!?!?! It IS part of the cover. :)

    Hey, really, though..........that is looking reeeaaalll nice. If you take that much care with the rest of the bike, you'll be up for some trophies:)

    Heck, that's almost pretty enough to be allowed to come to the carb clinic! LOL

    Dave F
     
  12. osprey1000

    osprey1000 Member

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    So quick update, The nut is firmly pissing me off. Not budging at all. So I took the fork off and am going to take it into work tomorrow to put it into a vise so I can put some serious torque to it. Hoping that will get the dang thing free. If Not I may be making a drive out to see you soon Dave.
     
  13. osprey1000

    osprey1000 Member

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    The nut finally came free. And the rest of the bolt was not too hard to get out. Someone did put WAY too much thread locker on it though. Which made it fun and challenging to get out. But the vise grips were stronger. And by too much thread locker, the last 15-20 threads were coated in the red stuff... yummy. Thanks again for the help Dave, back to polishing :)
     
  14. hogfiddles

    hogfiddles XJ-Wizard, Host-Central NY Carb Clinic Moderator Premium Member

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    No prob.................:)

    Dave
     
  15. Maxim-X

    Maxim-X Well-Known Member

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    Red thread locker, isn't that for machine bolt over 1/2"? Guess the guy didn't want to vibrate loose during a nuclear attack. Purple or maybe blue would probably be sufficient.
     
  16. osprey1000

    osprey1000 Member

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    Maxim-x, I would say that the nut with the lock washer proved to be sufficient since it held enough for me to break the bolt off...
     

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